At present, the paper industry is living in tough times. The recent economic downturn and ever-increasing costs make it hard for paper manufacturers to retain their profitability despite predicted market growth. Statistics show that the industry expects 25% expansion by the end of 2015. In order to meet this demand, paper makers will need to optimize their supply chains becoming leaner and smarter. Optima Control Solutions Ltd. provides answers to both challenges – cutting costs and improving efficiency.

Optima makes a significant engineering contribution to the paper making industry, the one sector forming over a third of the company’s business. This involvement stems from our deep understanding of paper making machines and the control systems that automate them. Our engineering team has successfully completed more than 120 full-scale projects for papermaking and converting companies.

Now in our seventeenth year, Optima have developed a strong portfolio of retrofit and upgrade projects. Successfully modernising a wide range of complex machinery manufactured by prominent OEM companies including:

  • Jagenberg
  • Pasaban
  • Wickeltechnick
  • Beloit Walmsley
  • Bone Markem
  • Valmet

We have completed a great number of control system upgrades on sheeting lines, slitters, winders/rewinders, embossing machines, coating lines and laminators.

At Optima we supply our engineering services to both end users and to specialist machine builders; a recognition of our specialist expertise in the sector.

Scope of Supply:

Having amassed valuable experience in the paper industry, we deliver excellent results through a fully integrated scope of services. On each project we undertake, we provide the following comprehensive project engineering components:

  • Detailed Site survey – To provide the level of competence and expertise required in complex retrofit projects it is essential that we understand every detail of the machine, its process and its control system. Whether the job is a simple upgrade of obsolete PLC hardware or a full-scale drive control system refurbishment, success is achieved by making the machine work faster and better and more reliably. This requires a fundamental appreciation of its working mechanisms.
  • Panel layout and panel build – High quality panel build is vitally important to any project if an efficient system installation and commissioning is to be carried out. It is also a significant element for a trouble free ownership and maintenance experience. Our panel build department is passionate about high build standards, continuously raising the quality bar.
  • Engineering of Drives/PLC/Programmable product software – Engineering a control system involves writing succinct, well structured and commented functional software. For drives, PLCs and SCADA, implementing complex control algorithms for machine control systems with clarity and accuracy is a pre-requisite if production efficiency improvements are to be gained.
  • Installation – We recognize that electrical installation is a critical part of any system upgrade project. Often the most visible part of a project we regard it as the signature applying both technical and aesthetic rigour. We offer a wide range of installation services, from complete control system panel suites and cabling through to individual drives and PLCs.
  • Commissioning – Turnkey project engineering involves complete responsibility. Successful projects have the least impact on productivity, so minimising the impact of machine downtime for any upgrade project is central to Optima’s planning process. Our engineers have the experience and expertise to deliver the best control solution, from start to finish and a well commissioned machine will provide the highest production efficiency, the best product quality and the most reliable machine. Critically, our engineers operate to ensure that site and machine safety always meet or exceed the requisite legal standards.

Previous Projects:

Tullis Russell

Coating line control system replacement

Upgrade of obsolete control system using Siemens S7 PLCs and Parker SSD AC motors and drives. Installation of MPS compliant safety system. Project value: £372,000

Sheeter control system upgrade

Supply of servo system to select the appropriate cutter gearbox ration. Modifications of the existing S7 PLC and HMI software to interface to the new equipment.

Slitting machine control system upgrade

Replacement of existing control system using Parker SSD DC drive controllers, Siemens S7-300 PLC, ultrasonic sensors, E-P converters. The project includes new control panel build.

Rewinder control system upgrade

Replacement of existing controllers and adding Siemens S7 PLC, HMI displays, PILZ PNOZ Multi safety PLC and emergency stop circuits.

Dandy roll upgrade

Upgrade of Parker SSD inverters and PLC hardware. Expansion of the PROFIBUS network.

Voith Paper

Felt production line control system

Design of PLC, Scada and Servo drives software. Modifications of safety system.

Belt machine control system design

The main control disciplines for this project include:
· Drive system engineering
· PLC system engineering
· SCADA system engineering
· Safety Engineering

Three roll assembly control system design

Design and supply of PLC and safety equipment/software. Build of main control panel and operator control desk.

SCA Hygiene

Conveyor control system software upgrade

Scope of supply includes site survey, PLC and Drive software write-up and training. Siemens control equipment is used.

J R Crompton

Paper machine drives upgrade

New control system design using Parker SSD and Siemens components. Conversion of original drives to standard format. Installation and commissioning .

Recent Posts

Drive System Retrofit for MasterDrives

Because of their superior functionality, comprehensive performance range and application flexibility, the Siemens Simovert MASTERDRIVES in CUVC, CUMC, Compact form and other variants has been a very successful drive system for single motor and multi-motor applications. The established common DC bus system enabled it to be used on demanding production machine processes across a wide range of industry sectors.

All good things must come to an end, but that doesn’t mean the end of the line for your production machine.

Optima’s innovative approach to upgrades significantly reduces the installation time and minimises risk to your site. All of our systems are thoroughly tested before they are shipped to site, completely eliminating any “out of box” failures.

Some of the benefits you will realise are:

  • Extended life span of your machine and increased availability due to continued spare parts supply with full support by Siemens
  • Improved productivity through lower energy costs and faster production cycles, through:
    • Simple operation monitoring using operator panel
    • User-friendly diagnostics with the STARTER tool
    • Additional interface options via PROFINET or PROFIBUS
  • Future-proofed due to access to the new world of TIA Portal

Optima’s approach for upgrades is to:

  1. 1.Analysis of your current machine configuration and potential further customer request
  2. Recommendation on the best replacement scenario
  3. Installation, configuration and commissioning of new  components and creation of circuit diagram and documentation
  4. Acceptance test and machine handover.

If requested, we can also provide training for all your relevant engineers and instruction of the operating personnel

Why Optima?

  1. We’ve been upgrading complex drive systems for over 20 years
  2. We are one of only 7 authorised Siemens Drives and Motion partners in the UK
  3. We provide a complete solution provided by one retrofit supplier including mechanical installation of motors and/or supply of adaptor plates and flanges to suit
  1. Don’t replace old for old. Replace old for new at a similar cost (including conversion) Leave a reply
  2. Weekend shutdown sees pump system upgraded to latest Siemens Sinamics drives and S7-1200 PLC Leave a reply
  3. First Batch of UL-Control Panels Finished and ready for shipping to the USA Leave a reply
  4. Improved Performance And Reliability Following Upgrade From Hydraulic Motors To AC Geared Motors Leave a reply
  5. Government Launches it’s “Made Smarter” Review 2017 Leave a reply
  6. Pepperl+Fuchs Innovation Tour arrives at Optima on the 14 November from 11.00 – 14.00 Leave a reply
  7. Automax and PLC 5 to PowerFlex Drives and Control Logix Upgrade on Metalliser Leave a reply
  8. Optima’s upgrade solution for a Sirpak 200 cut-to-length Machine system reduces waste by 9km per week Leave a reply
  9. Metal Decorating Press Upgrade using Siemens Simotion S120 + D425 controller + Simatic S7 PLC Leave a reply