CAST FILM LINE

Optima Control Solutions were commissioned by an end user to replace an ageing and obsolete variable speed drive system on an ER-WE-PA cast film line.

The age of the machine meant that the frequent maintenance necessary was proving expensive in terms of production downtime. The lack of readily available spares for the old drive control system was also causing major problems when failures did occur. The end user was faced with the decision of either investing in a completely new machine or updating the existing plant. The end user contacted Optima Control Solutions to discuss the feasibility of replacing the drive system.

We made an initial survey, from which a proposal could be made. As in most cases, the basic machine frame and main motors were sound, and very little costly mechanical work was necessary. From the initial proposal, a contract was awarded for a turnkey project to specify, supply, install and fully commission a new control system during the factory shutdown period.

The technical expertise required to apply today’s highly sophisticated drive equipment is difficult to resolve for most companies, as is providing the actual personnel resource for such a project. In replacing the variable speed drive system there were a number of advantages that Optima Control Solutions can offer. Our experience in the drives industry meant that they were able to manage and assume total responsibility for the project from specification and design, through to installation and commissioning. Independent technical advice was offered on the best types of standard drives and other control equipment available from a number of manufacturers, to provide the optimum technical solution. All equipment recommended was well supported with spares easily available in the UK.

Latest generation programmable drive equipment was used to interface to the existing machine motors. A PLC, Remote I/O and a Scada system were used to provide system flexibility.

As for any project, the specification formed a crucial part of the initial design activity. Based on a site survey, Optima Control Solutions took great care in producing a full specification document for approval by the client prior to the detailed design. The specification document ensured that the correct equipment was ultimately delivered, with minimal on site modifications necessary during the commissioning phase. Prior to shipment of the new drive equipment, full system testing took place of all hardware and software aspects with reference to the project specification. This further reduced commissioning time, resulting in an actual plant downtime of less than 4 weeks.

As a result of the machine upgrade project, the end user has benefited from a number of production enhancements namely excellent reliability, reduced maintenance, improved machine performance, faster machine set-up times and, ultimately increased production. These improvements were all achieved at a fraction of the price of a new machine purchase.