PROCESS CONTROL | MACHINERY


ality of this system will involve software upgrades, which Entek is exploring,” Burton says. Such control technologies move in to the realms


of Big Data. “The challenge with Big Data is not only capturing the data but presenting it in a readable way,” Burton explains. “That is why so many manufacturing companies are data rich, information poor. Given the tools we use at Entek, we do a good job of assessing and presenting vital plant metrics and making real-time decisions based on this, which is in the spirit of Industry 4.0.” The company is also working on simulation


processes. While full digital-twin capabilities are not utilised very often in controls, Entek says it routinely simulates processes at a lower level. For example, the company has developed a new set of standard code blocks which have built-in simulation features. An Entek Analog Input block can be used for simulating the level of a tank or a temperature, and this value can be calculated based on other block behaviour, such as pumps running at a certain speed, or heaters outputting a certain heat percent- age. While this is not a full simulation, the company says it covers much of the basics for simulating and testing a small pumping solution with a tank, or a heating system like an extruder barrel. According to Buss, the Switzerland-headquar-


tered manufacturer of kneader extruders, while the engineering industry traditionally moves slowly compared to automotive and other industries, it requires a high level of IT quality compared to consumer markets. The company’s Head of Business Development - Innovation & Digitaliza- tion, Dr Krischan Jeltsch, says this is because compounds are often the baseline for the manufacturing chains in sensitive industries such as medical, aerospace and automotive. Jeltsch adds that other


process control solutions requiring attention include unexpected downtime manage- ment, efficiency tracking and predictive maintenance. Key topics Buss sees reaching more mature states are condition monitoring/machine health, process/product quality control, service KPI monitoring, efficiency recording and full plant integration of engineering devices. Buss is currently progressing the development of its SenseHUB project by focusing on machine health and linking it to the company’s service organisation for maximum equipment uptime performance. SenseHUB is a cloud-based machine health monitor- ing product, which acquires various sensor-data,


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such as vibrations and oil status, for early interven- tion options in the case of anomaly detection. Jeltsch says that SenseHUB will grow modularly by adding new sensor types — beyond machine health monitor- ing — but enabling production and energy efficiency dashboards and added safety features.


Precise connections Industry 4.0 is revolutionising the plastics com- pounding and masterbatch processes and is ushering in a new era of efficiency, precision and connectivity, according to German twin screw extruder manufacturer Feddem. “With advanced technologies and real-time data analytics, we are witnessing a transformative impact on production, quality control and supply chain management. Embracing Industry 4.0 enables us to optimise material formulations, streamline operations and deliver exceptional value to our customers in this dynamic and evolving landscape,” says Klaus Hojer, Business Development/Account Manager at the firm. “The complexities of compounding demand


innovative process control solutions to address specific challenges effectively. By leveraging cutting-edge technologies, we can tackle issues such as batch-to-batch consistency, precise dosing of raw materials, uniform dispersion of additives and efficient energy consumption. These new process control solutions empower us to enhance product quality, reduce waste, optimise resource utilisation, and unlock the full potential of com- pounding operations,” he says. “In the realm of process control and Industry 4.0 initiatives for the plastics compounding and masterbatch industries, we are witness- ing several significant trends and influences shaping new develop- ments. Machine learning algo- rithms, and advanced data analytics provide additional


Below and right: Feddem has introduced augmented reality systems that allow for remote support and servicing


August 2023 | COMPOUNDING WORLD 51


IMAGES: FEDDEM


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