Plastics

Plastics inustry mediumThe 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.

Scope of Supply:

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:

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.

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
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