Plant & Works Engineering October 2022

SPECIAL FOCUS Production Engineering times of several months as well as astronomically high prices, which was of course not wanted. In addition, machine safety was no longer state-of-the-art.” In addition to the control system, Staveb’s retrofit offer also includes gears, drive and servo technology, safety and sensor technology, as well as measuring systems if required. The focus of every project is on operators and those responsible for maintenance, whose work is to be made easier. Human-machine interface solutions (HMIs) further simplify machine handling. In addition to ice cream production, Staveb has also modernised lines for filling sauerkraut, pasteurising fresh pasta, packaging hamburger patties, vegetables, or ready-to-eat salads. Solution Delica was already familiar with Staveb and Omron but had previously used solutions from other suppliers in terms of drive technology. In the modernisation project, everything was to be brought together. “The machine users should always have the same GUI in front of them,” Engler elaborates. Staveb has been using Omron controls for various retrofit projects since 2003. The customers benefit not only from the many years of expertise of both automation experts but also from the fact that they receive a solution that is customised for them from a single source and without a great deal of implementation effort. “We collaborate with Omron because they are very close to the customer – especially the application engineers are immediately on hand when a question arises,” explains Engler. The basis is the Sysmac automation platform in addition to Omron’s 1S drives with continuous integration from the NX/NJ machine controller to the software. With the Sysmac software platform, PLC functionality, motion control, robotics control, HMI, safety, and camera system can be seamlessly integrated and networked throughout. Sysmac has been used in PLC systems since 1971. “Sysmac is more open compared to other suppliers’ solutions and therefore makes production adaptations immensely easier,” says Reto Stenico, Area Sales Manager Switzerland at Omron. He says the platform allows users to react more flexibly to changes, control incorrect entries, and adapt more quickly to new market requirements: “It simplifies the line set up.” Less waste, faster packaging Another challenge that had to be overcome in the Delica project was that there are many different production changes: In addition to the different flavours, there are up to 30 different ice cream toppings and up to 20 different shapes that have to be taken into account with each production changeover. Previously, it could happen that up to 30,000 waffle ice creams could not go on sale during changeovers. Thanks to the more modern plant, production changes are now carried out without any rejects. Furthermore, the packaging processes are now between 10 and 20% faster. Retrofit project IoT, artificial intelligence (AI), or machine learning (ML) are often discussed in the context of Industry 4.0. But sometimes it doesn’t even have to be the big innovation push to rationalise production and give it new momentum. Stenico concluded: “Replacing a control system and the drive technology can often make a big difference when it comes to logging times, energy efficiency, or predictive maintenance.” Join us on Facebook Plant &Works Engineering Follow us on LinkedIn Plant &Works Engineering Followus on Twitter @PWEmagazine1 @PlantAssetMgt For the latest news visit the PWE website www.pwemag.co.uk PWE Plant & Works Engineering