Network modernization: Retrofitting for reduced downtime and enhanced output in plastics extrusion

In the automated industries of today and tomorrow, efficiency is paramount to success. This is particularly true in plastic extrusion, where precision and reliability are essential; a retrofit can significantly enhance performance. After years of operation, numerous systems require an upgrade to maintain the highest quality standards and reduce downtime.

A retrofit typically entails the replacement of defective components and the mechanical and software updates of machines. However, an often-overlooked aspect is the modernization of the communication network. A high-performance network is crucial for optimizing data flows between machines and enhancing the overall efficiency of the extrusion lines.

Edge devices serve a pivotal function in this context. They facilitate decentralized data processing directly at the machine level, resulting in accelerated and more efficient data handling. The implementation of edge devices provides several advantages, including:

• Real-time monitoring and control: Data is processed at the source, facilitating an immediate response to fluctuations in the production process.
• Minimized latency: As the data does not need to be transmitted to central servers, response times are considerably decreased.
• Enhanced data security: Sensitive production data is retained locally and does not require transfer over external networks.

Network Analysis

Another crucial step in optimizing production processes is commissioning through network analysis. By conducting a comprehensive examination of the existing network, vulnerabilities can be identified and addressed effectively. This results in:

• Optimized network performance: Bottlenecks and inefficient communication pathways are eradicated, enhancing overall network efficiency.
• Accelerated commissioning of new components: Network analysis facilitates the seamless integration of new devices and machines, thereby reducing commissioning time.
• Proactive maintenance: Potential issues can be detected and addressed promptly before they result in failures.

In general, we have conducted research on this topic, and you can find specific case studies online regarding network modernization and its impact on plastic extrusion.

• Digital Twins for Accelerated Start-Up of Production Processes: A case study on PVC pipe manufacturing illustrates the development of a digital twin (DT) aimed at minimizing start-up time in production while simultaneously monitoring product quality in real time. Through the implementation of DTs, the specified customer requirements regarding thickness and weight were met within minutes, thereby significantly enhancing process efficiency.
• Mechanical design automation: A further case study examines the automation of plastic extrusion tool design. Utilizing a CAD-based expert system, the time required to develop the design was diminished by 95-98%, illustrating the potential of automation and the incorporation of machine learning to enhance efficiency in plastic extrusion.

These case studies demonstrate how contemporary technologies, including digital twins and automated designs, can markedly enhance efficiency and quality in plastic extrusion.

It is evident that companies investing in modernizing their networks and integrating new technologies can enhance their production capacity while ensuring competitiveness in the global market. Consequently, the future of plastic extrusion may also depend on continuous improvement and adaptation to technological advancements.