Agidens supports TripleW in scaling Circulac® production with advanced process automation
Every year, more than 1 billion tons of food end up as waste worldwide. Since 2016, TripleW has been giving these side streams a second life by converting them into a sustainable raw material for bioplastics, household products and cosmetics. After a successful proof of concept, TripleW aimed to scale up to industrial level. Agidens provided the automation, SCADA visualization and data logging, establishing a robust foundation for a new generation of circular chemistry.
From waste to closed loop
How can we reduce the global waste mountain? TripleW found an answer in third-generation renewable raw materials derived from waste and by-products. With the right technology, food waste can be transformed into bioplastics.
TripleW developed a patented bioprocess that pulverizes and ferments organic side streams, then purifies them through multi-step separation into Circulac®, a bio-based lactic acid used as a building block for bioplastics (PLA) in applications such as toys and food packaging. Their chemical upcycling process also enables post-consumer PLA to be converted back into lactic acid, creating a truly closed loop.
Turnkey solution for circular chemistry
This innovative circular vision requires an approach where every valve and pump responds at exactly the right moment. On the first pilot line, it quickly became clear that limited automation and fragmented logging were holding back growth. For the second installation, TripleW therefore sought a partner with in-depth expertise in process automation, advanced SCADA-based control systems and centralized data logging.
Agidens began with a thorough analysis of the first pilot line and the intended functionality of the new installation. Based on this, our in-house experts designed a complete concept in which electrical engineering, cabinet construction, PLC software and SCADA configuration were seamlessly integrated. After approval of the design, we launched production of the electrical cabinets and preparatory software development. Electrical installation was carried out on site.
“Scaling up depends entirely on automation. That’s why we wanted a partner who not only shares our circular philosophy, but can also bring together all components into one data-driven solution.”
From design to practice
For the future-proof SCADA solution, Agidens relied on Ignition by Inductive Automation. Thanks to the Ignition Perspective Module, the visualization automatically adapts to different screen sizes, enabling all stakeholders to view and edit the interface on desktop, smartphone or tablet.
The intuitive user experience is ensured by the A_Lib typical library, developed in-house according to High Performance HMI principles. The library is seamlessly integrated with the underlying Siemens TIA environment (S7-1500 controller). Here too, the A_Lib software standard safeguards modular and sequential control.
During the Factory Acceptance Test (FAT), the entire process was reviewed virtually. The subsequent Site Acceptance Test (SAT) validated integration with the physical equipment. Finally, the software was fine-tuned during commissioning.
The project concluded with targeted training sessions for operators and R&D teams, including scenario exercises for deviation management and reporting. TripleW now operates an installation that runs reliably around the clock and can be continuously optimized.
“Agidens thinks along and ahead. Exactly what we needed to scale up to industrial level with full confidence.”
The result
Thanks to this integrated approach, TripleW now operates a stable, scalable pilot installation with full-scope automation, an intuitive SCADA interface and centralized data logging. In short, the ideal foundation to produce Circulac® at commercial scale, with:
Reliable process control
All critical components are automatically synchronized. The SCADA system manages 13 pumps, 8 motors, 3 external units, 41 valves and 26 automated sequence controls.
Real-time insight
The SCADA dashboard accurately tracks data and immediately signals deviations, enabling faster response. With the flexible Power Chart component in Perspective, both operators and engineers can quickly visualize and monitor process values as well as current and historical trends.
Data-driven optimization
The system incorporates around 20,000 tags and logs all relevant process data historically via the Ignition Tag Historian Module. This provides a scalable solution for storing time series data. Structured logging accelerates R&D cycles and supports future scale-up.
Modular software architecture
Thanks to Ignition’s modular architecture and the scalability of the TIA controller, the installation is fully prepared for future expansions or integrations.
Want to know more?
With this second pilot installation, TripleW and Agidens demonstrate that circular chemistry is both technologically viable and industrially scalable. An integrated automation and data-driven approach form the backbone for stable production, fast optimization and smooth scale-up. This paves the way to launch Circulac® at commercial scale and transform food waste into valuable raw materials once and for all.