Drives, PLCs and SCADA and controls are fundamental to the converting
industry, companies naturally rely on their machine control systems for
production. More recently however, enterprising companies have developed their
control systems to commercial advantage.
Advances in drive and control technology have meant that system reliability has
improved so much that it is virtually taken for granted. The control equipments
ability to meet health and safety regulations and to provide wide ranging general
functionality is also regarded as a given.
However, along with safety, manufacturers now assess their machine controls in
the context of improving production efficiencies, targeting faster operating
speeds and quicker changeovers, higher production standards and improved
energy consumption – all cost factors which can help converting companies
become more competitive.
Optima Control Solutions Ltd. is a leading control system integrator operating at
the leading edge of this technology since 1995. The Blackburn-based company’s
managing director, Michael Hill, believes that suppliers of machine control
systems to both OEMs and end users must measure success by analysing the
effect on the customer’s operating efficiency.
One business which reaped the benefits that upgrading to Optima’s state of the
art drive and control technology can provide is leading papermaking, coating and
converting company Tullis Russell in Scotland.
Tullis Russell was concerned that its ageing Jagenberg Vari-Dur 120 Slitter-
Rewinder was having a detrimental affect on the operational performance of its
Glenrothes site and decided to replace the original analogue components with
new digital technologies.
Optima Integrated a Siemens PLC and HMI, Parker SSD drives, ABB tension
control, Pilz safety equipment and Sick optics, subsequently transforming the
machine’s performance and helping Tullis Russell post a five percent
improvement in its OEE and an associated 25 percent increase in productivity.
Intelligent, networked drives and high performance tension measurement
equipment now operate the complex load-sharing algorithms that provide reliable
and improved winding performance, while automatic sequencing of the machine
operation has improved its operational repeatability.
Mr Hill said: “When considering a control system upgrade, OEE might not be as
obligatory as safety improvements, nor as unavoidable as the fundamental need
to keep the machine running. However, the intelligent integration of modern drive
and control technology in this upgraded Jagenberg Vari-Dur 120 control system
has had a significant impact on the production efficiency of the machine.”
BACKGROUND
Optima Control Solutions Ltd is an independent company and industry leading
specialist in variable speed drive, PLC and SCADA applications, serving multisector
manufacturing industries since 1995.
The company’s expertise has helped to upgrade unreliable machinery for its
clients to achieve faster operating speeds, higher quality, improved availability
and considerably extended their plant operating lifetimes at a fraction of the cost
that new machinery carries.
Infoserve365 is part of the Optima Group, whose wealth of skills and experience
covers the application, design and support of variable speed drive equipment
across a wide range of industries, including paper, packaging, plastic film
extrusion, printing, cable and wire, rubber, metal processing and textiles.
Optima’s knowledge of leading edge technologies coupled with recognised
application expertise provides a powerful and cost effective resource to machine
builders across many industrial sectors.
As at February 8 2010