Client:

Category: Process Control Room

Image 1 | JST control room: A look inside the new control room at PS Biopolymer GmbH & Co. KG in Stade. The modern control room environment brings together all production data from an MC/HPMC plant and provides the basis for safe, efficient plant control in 24/7 operation.

Image 2 | JST operator workstation: Ergonomics meets automation: After logging in with JST myLogin® software, the height-adjustable Stratos X11® control room consoles automatically adjust to the individual working height. The result is a workstation that adapts to the person - not the other way around.

Image 3 | JST operator workstation: Everything in view without turning around: The concave arrangement of monitors and console follows the operator’s natural line of sight - allowing focused work with minimal movement.

Image 4 | JST ergonomics: Maximum flexibility at the workstation. 3D articulated arms with multiple adjustment options allow precise positioning of the workstation displays and ergonomic adaptation to each user - ensuring optimal viewing angles.

Image 5 | JST ergonomic concept: A tidy workspace down to the last detail: Brush seals keep cables out of sight and create a clean, uncluttered working environment - even with extensive technology in use.

Image 6 | JST operator chair: Ergonomic, robust and individually adjustable: JST control room chairs are specifically designed for continuous operation and support operators with flexible adjustment options - from the seat and backrest to the armrests and headrest. They offer a high level of seating comfort and ergonomic support, even during long shifts.

Image 7 | JST control room concept: In addition to the operator workstations, further engineering workstations have been integrated at the rear of the room. They allow adjustments and optimisations to be carried out directly on site - without interfering with ongoing operations.

Image 8 | JST OPAL X11®: Optimised room acoustics and pleasant lighting conditions create a calm, focused working environment during normal operation.

Image 9 | JST Stratos X11®: Clean lines and an uncluttered rear view define the appearance of the operator consoles. Spacious access panels keep everything organised and provide easy access ...

Image 10 | JST Stratos X11®: ... behind them is an illuminated service compartment with ample space for power and network infrastructure - neatly organised and easily accessible for maintenance and expansion.

Image 11 | JST custom furniture: a bespoke solution tailored to customer requirements: The central control panel unit, including a filing cabinet, was precisely integrated into the console arrangement - functional, ergonomic and perfectly suited to its intended application.

Image 12 | JST CommandPad®: centralised touchscreen control: The myGUI® user interface is displayed on the JST CommandPad®. Its clearly structured interface allows all applications in the control room to be intuitively displayed, moved and operated - quickly, flexibly and seamlessly across systems.

Image 13 | JST video wall: visualisation as the key to plant control: The large-scale display solution combines the process control system and additional data sources into a unified overview. This allows the operator to keep track of all processes at a glance. Critical conditions become visible at an early stage.

Image 14 | JST video wall: JST’s QuickOut system makes it possible to access individual displays for maintenance, even during ongoing operations. A light touch is all it takes to gently move a monitor forward, providing access to the technology behind it.

Image 15 | JST video wall: more than just display space: The large video wall becomes an integral part of the room. It can be customised to meet local requirements - for example, with integrated cabinets that provide additional storage and help maintain an uncluttered environment.

Image 16 | JST custom furniture: made to measure for the entire room: The cabinet units were custom-built and consistently reflect the control room’s design concept - creating a clean, cohesive appearance.

Image 17 | JST conference room: a decision-making space with direct access: The conference room is technically connected to the control room and can display all relevant sources when needed - an important basis for rapid coordination in critical situations.

Image 18 | JST TacticTable®: lighting as a design element: The integrated LED lighting offers a wide spectrum of colours. It emphasises the clean lines and adds carefully placed design accents to the conference room.

Image 19 | JST conference room technology: video wall and audio integration: A video wall with four large-format displays can also show control room content in the meeting room when required. Integrated speakers provide audible warnings in the event of an alarm.

Image 20 | JST myLogin®: keycard login: The system also provides quick and secure access to personal settings and permissions in the conference room.

Image 21 | JST equipment room: technology housed separately: The central system equipment is located in a separate room. This reduces heat and noise in the control room while also protecting the sensitive infrastructure.

Image 22 | JST MultiConsoling®: at the heart of the KVM architecture: The MultiCenter handles central signal distribution and is designed with redundancy - ensuring maximum availability and fail-safe operation around the clock.

Image 23 | JST system control: combining security and flexibility: The myGUI® Controller enables strategic management of access rights and roles for all sources. Together with GrabberVM® technology, virtual machines can also be seamlessly integrated into the system environment.

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Control rooms in transition: system migration and increasing process complexity

The requirements placed on industrial control rooms are changing noticeably. More complex processes, increasingly interconnected digital workflows and evolving process control technology are creating new demands and prompting companies to rethink established concepts. At its Stade site, PS Biopolymer GmbH & Co. KG has taken precisely this step. The result: A comprehensive turnkey solution from JST – Jungmann Systemtechnik® was used to implement a control room project consistently geared toward the challenges of the future.

From system migration to a new control room

Some projects begin with a technical necessity – and develop into a strategic decision. This was also the case at the Stade site: As the existing process control system (PCS) was no longer supported, PS Biopolymer GmbH decided to undertake a PCS migration and build a new control room.
Wolfgang Täuber, Project Technology Lead and responsible for the MC/HPMC plant, recognised early on that the undertaking involved much more than new technology. “We had to look at how to migrate everything and coordinate the operation of all digital systems as effectively as possible in day-to-day plant operations,” he explains, describing the starting point. What began as a change of process control system thus became a future-oriented project for a plant in which all processes must interact precisely in 24/7 operation.

A plant in continuous operation

All information converges in the control room. Here, the production trains of an MC/HPMC plant are monitored continuously, while all plant activities are coordinated. For the operators, this means maintaining an overview of conditions, processes and deviations at all times within a highly interconnected production environment. This led to the central task: ensuring safe and efficient plant operation.
According to Wolfgang Täuber, the focus was therefore on providing targeted support to the operators rather than overwhelming them with technology. To achieve this, the new control room had to do one thing above all: visualise complex plant operations clearly and enable effective control.

Process visualisation and effective operation

JST therefore uses a solution that brings together visualisation, ergonomics and ease of operation. At its heart is the MultiConsoling® system, a fully redundant control system for the operator workstation, video wall and even the systems in the adjoining conference room. Together with the myGUI® user interface, it ensures intuitive control of all applications. The potential future integration of virtual machines via the JST GrabberVM® system was also anticipated.

From the 1990s into the future

The visual transformation is equally remarkable: The control room with process control technology from the 1990s has been replaced by a new control room that consolidates information, streamlines workflows and sharpens the focus on what matters most. A large-scale video wall designed for continuous operation, the ergonomic, height-adjustable Stratos X11® control room console, OPAL X11® acoustic ceiling sails and custom-made functional furniture provide the foundation for this.

Making complex processes manageable

The Stade project is a prime example of how modern control room technology can help make multifaceted production processes manageable. Not by adding more personnel, but through systematic optimisation of the technical infrastructure, clear visualisation and a well-designed working environment. The result is a solution that meets the growing demands of industry – while keeping people at its center.

“The demands placed on control rooms are continuously increasing. Our task is to support people and ease their workload through intelligent system architecture and clear operating logic.”

Rafael Paltian

Sales Consultant, JST – Jungmann Systemtechnik®

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