Quimikao Uses Process Automation and Virtualization Technologies

PlantPAx system architecture provides control, visibility and improved industrial system security

Background

Japanese chemical company Kao made its name in the late 19th century as Japan’s first domestic soap manufacturer. The company’s soap, named Kao Sekken, cleaned up despite the dominance of import soaps and eventually established a foothold in the Japanese consumer marketplace.

The success of Kao’s soap helped fuel the launch of the company’s other personal and home-care products, from moisturizers and shampoos to oils and detergents.

Today, Kao is a leading chemical company that has expanded its reach far beyond Japan, with more than 33,000 global employees across its consolidated companies and more than $11 billion in annual net sales.

Among Kao’s global businesses is Quimikao, which was established near Guadalajara, Mexico, more than 35 years ago.

Today Quimikao produces products for the North and South American, Asian and Australian markets.

The company primarily produces cationic surfactant derivatives of fatty acids for use in a wide range of products, from fabric softeners and fragrance compounds to asphalt emulsifiers and corrosion inhibiters used in petroleum.

Quimikao recently decided to establish a new plant in Mexico to meet growing demand for nitrile, a chemical base for liquid detergents, fabric softeners and other products.

Rather than designing the new facility from the ground up, Quimikao opted to replicate an existing Kao Japanese plant using locally sourced process automation controls and support services.

Challenge	Construct a greenfield facility in Mexico to meet growing production demand Model design of new facility after a chemical plant in Japan, but use a North America-based control system supplier to reduce language and time-zone barriers
Solutions	PlantPAx Process Automation System Virtualized Infrastructure
Results	Increased redundant control and visibility into all aspects of processing Increased production efficiency, and improved product quality and consistency