Tank Farm and Transfer Automation

Intelligent automation systems that orchestrate product movement, inventory management, and process control across complex facilities.

Product Overview

Our tank farm and transfer automation systems provide centralized control of product storage, routing, and movement throughout processing facilities. These systems integrate sensors, valves, pumps, and controls to automate transfers, track inventory, prevent errors, and optimize production flow. With real-time monitoring, automated CIP routing, and comprehensive reporting, our automation solutions increase efficiency while reducing manual intervention and contamination risks.

Key Benefits

  • SCADA systems provide centralized monitoring and control
  • Automated transfer sequences prevent product cross-contamination
  • Level sensors and alarms prevent tank overflows
  • Product tracking from receipt through packaging
  • Automated CIP cycle management ensures thorough cleaning
  • Energy optimization through efficient pump scheduling
  • Historical data logging supports quality investigations
  • Integration with ERP systems for inventory management
  • Reduces manual operations and associated safety risks

Industries Served

  • Brewing & Distilling
  • Beverage Production
  • Dairy Processing
  • Wine & Cider
  • Food Manufacturing
  • Chemical Processing
  • Pharmaceutical Production
  • Biofuels

Compliance Capabilities

  • FDA 21 CFR Part 11 (Electronic Records)
  • cGMP requirements
  • FSMA traceability requirements
  • ISA-95 standards for automation
  • Cybersecurity standards (IEC 62443)
  • GAMP 5 for pharmaceutical systems
  • Batch record documentation

Product Breakdown

  • Storage Tank Systems: Vertical or horizontal tanks (500-50,000 gallon capacity) with level monitoring, temperature control, and agitation systems managed through centralized automation for wine, beer, spirits, and liquid food products
  • Automated Valve Matrices: Pneumatic valve arrays (10-100+ valves) with PLC sequencing enabling routing from multiple sources to multiple destinations with interlock logic preventing invalid transfer paths and cross-contamination
  • Transfer Pump Stations: Centrifugal or positive displacement pumps (5-200 HP) with VFD control, flow meters, and automated priming systems delivering 10-500 GPM with energy-optimized operation and predictive maintenance
  • Inventory Management Systems: Real-time tracking of product volumes, locations, and ages using load cells, radar, or ultrasonic level sensors with automated reporting and integration to planning systems for production scheduling
  • CIP Routing Automation: Automated cleaning circuit selection with valve sequencing, flow verification, and return-to-service checks ensuring all product contact surfaces are properly cleaned between products or batches
  • SCADA and Control Systems: Supervisory control systems with graphical HMI displays showing tank status, transfer progress, and system alarms with remote access capabilities for 24/7 monitoring and mobile device support

Technical Details

  • Level Instrumentation: Radar (±2mm accuracy), ultrasonic (±5mm), or hydrostatic pressure sensors with 4-20mA outputs providing continuous level monitoring and high/low alarms preventing overflows and pump cavitation
  • Valve Automation: Pneumatic butterfly, ball, or diaphragm valves (1"-12" sizes) with position feedback sensors and fail-safe spring return ensuring proper valve positioning with automated stroke time monitoring
  • Flow Measurement: Magnetic or Coriolis flow meters (±0.5% accuracy) measuring 1-500 GPM with totalization functions tracking product transfers and providing data for yield calculations and inventory reconciliation
  • Temperature Control: Glycol or direct expansion cooling systems with proportional control valves maintaining product temperatures from 28-85°F (±1°F accuracy) with zone control for large storage vessels
  • Control Architecture: Allen Bradley, Siemens, or Schneider PLCs with redundant processors and I/O modules, Ethernet/IP or Profinet networking, and UPS backup ensuring 99.9% uptime for mission-critical operations
  • SCADA Software: Wonderware, Ignition, or FactoryTalk platforms with graphical tank displays, trend analysis, alarm management, and recipe-driven transfer automation with electronic batch records for compliance documentation