Control Systems For The Plastics Industry

Extrusion - Click to Enlarge

The plastics manufacturing sector is vast so it is no surprise that 25% of Optima’s business is conducted in this sector. With such a variety of processes involved in plastic production, broad ranging yet expert control knowledge is a necessity.

From extrusion to coating & laminating, specialist process understanding is needed to guarantee product quality. Critical variables such as speed, temperature and tension are dependent upon a robust control system.

A well-designed control system upgrade can also significantly improve the operating efficiency of a production line and when compared to the price of a new machine does so at a fraction of the cost.

Optima Control Solutions Ltd. have completed more than 30 major projects for the plastics industry. Upgrading control systems on critical production plant for many industry-leading companies.

Installed plant built by OEM’s such as ER-WE-PA, Bruckner, Davies Standard, Riefenhauser, Egan, Windmoller & Holscher [amongst others] form part of Optima’s impressive portfolio of upgrades.

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  • Services:

    
    

    In addition to a number of full-scale engineering projects in the plastics industry we have years of experience in related industries - packaging and converting, to name a few. Some of the service components we offer include:

    Detailed site survey – As automation experts we find solutions only to the problems we fully understand. A complete site survey allows us to design the most appropriate control system within budget, deadlines and special requirements.

    Panel layout and panel build – The quality of a control panel build is critical to the functionality of a production line. We design and build our panels according to highest standards in order to minimize ownership and maintenance costs.

    Engineering of Drives/PLC/Programmable product software – Sometimes, besides complex hardware replacements, a tailored software engineering solution might be the only answer to improving an extruder’s performance. Our automation engineers are experts in writing SCADA and PLC software, some of them with more than 16 years of experience.

    Installation - Electrical installation is something we do with confidence. We are able to offer a wide range of installation services such as installation of drive PLCs, remote I/O hardware and cables to the drive controllers.

    Commissioning – Total responsibility is what Optima’s experts have besides their valuable engineering skills. We provide on-site and system design commissioning in order to ensure smooth run and minimum downtime of a coating line, for example. Legal safety standards are always met or exceeded when our engineers complete a job. They also make sure that all operator controls are functionally tested.

• Previous projects for the Plastics industry

  • Previous projects completed:

    
    

    Britton Taco

    
    

    Cast Film Line

    
    

    Refurbishment of a ER-WE-PA machine control system

    
    

    Machine supervisory system

    
    

    Allen Bradley - RSView SCADA

    
    

    PLC for machine control

    
    

    Allen Bradley ControlLogix PLC

    
    

    Variable Speed Drives

    
    

    Parker Hannifin/SSD 590+ DC drive controller – DeviceNet communications

    
    

    Panel Build

    
    

    Supply of new multi-bay control cubicles and operator desks

    
    

    Installation & Commissioning

    
    

    Turnkey project – Electrical, mechanical installation and commissioning

    
    

    DuPont Tejin Films

    
    

    Cast Film Line & Coating Head

    
    

    Refurbishment of a Casting Drum, Stenter, Coating Head and Twin Turret Rewinder control system

    
    

    Machine supervisory system

    
    

    Allen Bradley - RSView SCADA

    
    

    PLC for machine control

    
    

    Allen Bradley ControlLogix PLC

    
    

    Variable Speed Drives

    
    

    Parker Hannifin/SSD 590+ DC drive controller – DeviceNet communications
    Indramat DC Servo drive controller – High accuracy speed control with low torque ripple for control of Casting Drum

    
    

    Panel Build

    
    

    Supply of new multi-bay control cubicles, operator desks and operator panels

    
    

    Installation & Commissioning

    
    

    Turnkey project – Electrical installation and commissioning

    
    

    Tensar International

    
    

    Biax Line

    
    

    Refurbishment of a Geosynthetic manufacturing line control system

    
    

    Machine supervisory system

    
    

    Siemens - WinCC SCADA
    Two separate WinCC SCADA’s individually controlling entry and exit sections Redundancy provision for either SCADA to control the complete line

    
    

    PLC for machine control

    
    

    Siemens S7-317
    Siemens ET200S distributed I/O

    
    

    Variable Speed Drives

    
    

    Parker Hannifin/SSD 590+ DC drive controllers – Profibus communications
    Parker Hannifin/SSD 690+ AC drive controllers – Profibus communications

    
    

    Safety

    
    

    2 x Pilz PNOZmulti programmable safety controllers – Safe speed monitoring and hold to crawl functionality

    
    

    Panel Build

    
    

    Supply of new multi-bay control cubicles, operator desks and operator panels

    
    

    Installation & Commissioning

    
    

    Commissioning of the control system

    
    

    Linpac Group

    
    

    Extrusion Line control system upgrade

    
    

    Refurbishment of a food packaging line control system

    
    

    Machine supervisory system

    
    

    Siemens – MP277 HMI

    
    

    PLC for machine control

    
    

    Siemens S7-315

    
    

    Variable Speed Drives

    
    

    Parker Hannifin/SSD 590+ DC drive controllers – Profibus Communications
    Parker Hannifin/SSD 690+ AC drive controllers – Profibus Communications

    
    

    Panel Build

    
    

    Supply of new control cubicle and operator panel

    
    

    Installation & Commissioning

    
    

    Turnkey project – Electrical installation and commissioning

    
    

    3M Guinn

    
    

    GVE Metaliser

    
    

    Refurbishment of a high speed Vacuum Metaliser

    
    

    Machine supervisory system

    
    

    Allen Bradley - RSView SCADA

    
    

    PLC for machine control

    
    

    Allen Bradley ControlLogix PLC and distributed I/O

    
    

    Variable Speed Drives

    
    

    Allen Bradley PowerFlex 700 AC drive controllers –
    ControlNet communications
    Parker Hannifin Stepper drive controllers

    
    

    Installation & Commissioning

    
    

    Commissioning of the control system

    
    

    Habasit

    
    

    Embossing machine control system

    
    

    Complete control system design including control cubicles, control desk Facia and emergency stop system.