ABHR finds out how packing operations are benefiting from intelligent system networking from Haver & Boecker.
Increasingly, manufacturers of bulk products are realising the benefits of networking their packing machines with intelligent monitoring and analytics platforms to reduce unplanned downtime, increase production and improve safety, among other factors.
Haver & Boecker, a leading developer and manufacturer of packing technology for bulk, powdery products in the cement, chemical, building materials and food industries, is at the forefront of this aspect of Industry 4.0.
Haver & Boecker sales engineer Alexandre Santi told ABHR networked machines are less prone to stoppages and are quick to signal potential maintenance issues, which minimises waste and resource use.
“By utilising digitisation for process monitoring, control, analysis and optimisation, you can ensure your plant runs at full efficiency and with optimised processes that minimise consumptions and disruptions,” he said.
Digitising packing
Haver & Boecker’s QUAT2RO system provides users with an intuitive networking, monitoring and analytics solution with a variety of features that can be customised to the customer’s requirements.
The system can integrate a monitoring platform for real-time data and has an analytics tool to help diagnose problems.
It can make long-term interpretations of system data in a way that optimises service calls and repairs for maximum efficiency.
“These technologies automatically, effortlessly and securely provide live data that can signal potential maintenance issues while enabling deep new insights into machine productivity, scrap rates and more,” Santi said.
Available data and insights include the ability to monitor the production performance of machines in real-time, recognise signs of wear at an early stage, increase efficiency by comparing different machine data, proactively plan maintenance intervals based on machine data, check the effect of machine settings and optimise resource planning.
“A key offering of QUAT2RO is the direct live connection you get to one of our OEM service experts. With the use of cameras and smart glasses, they can diagnose issues and provide solutions remotely,” Santi said.
Available data and insights include the ability to monitor the production performance of machines in real-time, recognise signs of wear at an early stage, increase efficiency by comparing different machine data, proactively plan maintenance intervals based on the machine data, check the effect of machine settings and optimise resource planning.
“A key offering of QUAT2RO is the direct live connection you get to one of our OEM service experts. With the use of cameras and smart glasses, they can diagnose issues and provide solutions remotely,” Santi said.
Manufacturer goes Industry 4.0 with QUAT2RO
Chemical and building materials manufacturer KLB Kötztal GmbH is known for its high standards of quality and service. This has been achieved through its innovative concepts, extensive expertise, and efficient production.
When the company wanted to modernise its manufacturing facility to an industry 4.0 standard, it needed a technology partner that would ensure it upheld this reputation.
After engaging Haver & Boecker to engineer and supply the new mixing plant, comprising mixers, silos, tanks, and containers, along with numerous scales, conveyor screws, pumps, pipelines, and various other components, it was time to ensure KLB had complete visibility and control over the new facility’s operation and performance.
By implementing QUAT2RO, the entire packing chain was networked and made visible on a user-friendly dashboard. Operators could now monitor the plant in real time from anywhere, anytime. They had access to deep analytics to facilitate ongoing optimisation and the option for remote diagnostics by a Haver technician if required.
With QUAT2RO, KLB is now delivering consistent product quality. All product components are precisely weighed and transported to the mixer in the correct amount and order, and optimal mixing duration and speed are achieved.
The company can trace all processes and raw materials without any gaps. It is capable of managing an unlimited number of recipes and can configure control recipes individually. It also seamlessly handles the creation and scheduling of orders, the generation of batch logs, reports, and statistics, as well as the automated management and documentation of production data, material consumption, inventory, and finished products.
The results are both tangible and measurable: machines and systems are more efficiently utilised, resources such as raw materials, energy, and time are saved, and errors are minimised.
KLB’s new mixing plant has achieved two essential requirements: the precise and reproducible mixing process management and the central monitoring and easy operation of all connected plant components.
Santi said Australian operations can also benefit from QUAT2RO.
“We work closely with our customers to analyse the requirements of their existing packing operation to configure a customised solution that’s right for them,” he said.
“We then plan the installation and training of employees and remain available to assist with the system when needed. Having the kind of data available that QUAT2RO opens up enormous opportunities for reducing costs and improving profits.”
