INDUSTRY 4.0 | FACTORY MANAGEMENT
Adding intelligence to compounding
Capturing and, more importantly, utilising production data is a key element in compounding plant process efficiency
improvement.Peter Mapleston finds out more
State-of-the-art data acquisition, processing and analysis can significantly simplify the daily production routines of compounding companies and provide valuable in-depth information for process optimisation. Progress in both hardware and software for “smart” manufacturing continues at a fast pace with providers increasingly adapting their offerings to take account of what compounders really need and to ensure they deliver the maximum gains. This article takes a look at some new developments that will help compounders position themselves better for the fourth industrial revolution — Industry 4.0. Plastics compounding equipment manufacturers
are making progress with their Industry 4.0 developments. Having presented its Industry 4.0 and process control visions at K2019 last October, Coperion says it has now integrated the Smart Machine Features into the first production twin- screw extruders. Integrated into the machine control technology,
the Smart Machine Features comprise a package of different functions that are designed to help reduce waste material, increase the availability of the
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machine, and allow earlier detection of processing issues. The company says it has used its extensive process know-how to ensure the control system is able to monitor all the process conditions and detect deviations that could affect product quality. “We are very confident that the Smart Machine
Features will help our customers to prevent production of large amounts of off-spec material and even reduce their effort in quality control in the future,” says Markus Schmudde, Head of Research and Development, Compounding & Extrusion, at Coperion. “Today’s machine operators have many tasks to perform which are not necessarily located at the extruder, so the immediate detection of failures becomes less likely. Coperion’s Smart Machine Features can help to overcome this issue by actively informing operators in case of problems.” For preventive maintenance Coperion offers a condition monitoring system for the extruder drivetrain, including the gearbox. This system helps to reduce maintenance costs and to detect possible failures early enough to prevent long-time production stops caused by severe and sudden damages. “This system is perfectly integrated into
Main image: Capturing and making effective use of in-plant data promises to lift productivity and quality across the compounding industry
August 2020 | COMPOUNDING WORLD 49
IMAGE: SHUTTERSTOCK
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