Projects

We have engineered hundreds of projects with values up to £500,000. Below are details of some of our upgrades:

EMP Belt Line for Kunshan, Jiangsu Province China. Design, supply, commission control system for a belt manufacturing machine. Fully integrated Siemens solution comprising PLC, SINAMICS Drives, WinCC, PROFISafe system (safety integrated PLC).

 

 

 

Lithographic Aluminium Strip Line for Zheng Zhou. Turnkey project for strip processing line, 14xSiemens AC SINAMICS Drives, Siemens PLC, SCADA, Servo drives, PROFISafe. Totally integrated package makes lithographic plate for use in the printing industry.

 

 

Paper coating machine. Design, supply, installation and commissioning of complete drive system retrofit to their paper coating line. 98xAC Vector Drives, 13xDC Section drives, 40A to 720A.

 

 

4x off Jagenberg Dual-roll rewinder. Complete control system upgrade for 4x Jagenberg dual-roll winders. Complete pneumatic, electrical and safety system upgrade on the machine. SSD DC Drives, Siemens S7-300 PLC, PILZ, PNOZ Multi Programmable safety.

Dual-roll MYLAR coater control system. Design, supply, commission on two-sided coater for MYLAR product, Siemens S7-400 PLC, Reliance Drives, Rockwell SCADA.

Dual-roll Tyvek coater control system. Design, supply, commision on dual-roll gravure coater, 4xAC Vector drives in load-share, flotation oven and floatation air-turn unit control, GE Fanuc PLC, Cimplicity SCADA, Siemens Drives (Micromaster, Masterdrives)

Process Line Ltd. Italy

Aluminium Strip Line for Verona Lastra Italy

Makes lithographic plate for use in the printing industry.

Process Line Ltd. South Africa

Aluminium Strip Line for First Graphics, South Africa.

Makes lithographic plate for use in the printing industry.

Crown Paints, Darwen

5x palletising line upgrades for paint tins/

News Siemens PLC control system for 5xpaint tin palletising lines.

Replaced obsolete Siemens SIMATIC 505/535 PLC.

Linpac Packaging, Yorkshire

Extruder 71 Control Panel Replacement.

Produces plastic film which is vacuum formed into containers for various foods.

Main extruder and melt pump replacement, Siemens PLC, SSD Drives solution.

CCL Decorative Sleeves

DCM Printing Press Modifications.

Design, supply and commissioning of a new drive system for their existing print machine.

FFP Packaging, Northampton

Wax Machine Line Drive System.

Design, supply and commissioning of a new DC drive system for their wax coating line.

Flexel International, Glenrothes, Scotland

New control system for a printing/laminating machine

Design, supply and commissioning of a new machine control system for manufacturing Ecofilm under-floor heating. Flexel International are one of the largest manufacturers of under-floor, ceiling and compact panel heating elements.

Kodak Ltd

Control System for Jagenberg machine.

High speed cutting line including rotary shear control system.

Aluminium Strip coating line control system.

Outokumpu Stainless Ltd.

Foil Annealing Line control system.

Including Wonderware SCADA package, GE Fanuc PLC, Parker SSD Drives.

Lawson Mardon Flexibles

Sciavi Printing Press Refit – Turnkey Package

DuPont Teijin Films Ltd, Wilton

Stenter Line Drive System – Turnkey Package

C Perkin Ltd.

Cardboard Tube Machine – High speed Siemens servo drive application.

Manufacturing cardboard tubes at linear material input speed of 100m/min.

Recent Posts

Continued Upgrade of Batch Plant

Batch Upgrade

When our customer needed to upgrade their aging batch processing and bulk delivery systems on site, they turned to Optima Control Solutions.

Optima were tasked with migrating the legacy control system over to  a modern integrated batch control solution with no disruption to production

APPROACH

A Rockwell Automation solution was installed, which included

  • ControlLogix PLC upgrades in each mixer / bulk system
  • Redundant Server running FactoryTalk ® Batch
  • EtherNet/IP device-level ring network topology

RESULTS

  • Reduced obsolescence risk and downtime
  • Site-wide familiarity of operator interfaces for each process
  • Ability to develop recipes away from the factory floor or off-site for ease of deployment and remote support for timely intervention in the event of any equipment malfunction
  • Reduced batching errors caused by operators

Becuase the system runs from a central batch server, the customer has the ability to develop recipes away from the factory floor or off-site for ease of deployment,. This reduces batching errors that may be caused by operators

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