Smart Digital Tools Boost Twin Screw Extruder Efficiency and Sustainability in Masterbatch Manufacturing
The Coperion C-BEYOND digital platform has been used by Remscheid, Germany-based masterbatch maker colorplasticchemie Albert Schleberger GmbH (cpc) to improve its ZSK twin screw extruders, ensuring long-term optimal efficiency for both the extruders and the entire production process. This technology logs every ZSK extruder’s operating parameters at CPC in a cloud, making them instantly accessible for insightful analysis.
The OEE (Overall Equipment Effectiveness) value of each ZSK extruder as well as the plant as a whole can be found at any time using C-BEYOND. Additionally, the cpc platform supports order planning. Real-time production amount data is accessible. C-BEYOND allows for detailed documentation of the production process and optimal scheduling of maintenance tasks. Furthermore, C-BEYOND computes CO2 emissions and energy usage per kilogram of masterbatch generated. The information it captures greatly speeds up and improves Coperion’s remote servicing effectiveness.
OEE dashboard: clear overview of extruder performance
“We produce exclusively tailor-made products for our customers on our ZSK extruders. Production quantities from 25 kg on up are possible. Within a single day, the masterbatch recipes have to be changed frequently. And precisely for this reason, forward-looking order planning and the shortest possible machine downtimes between tasks are critical for our production efficiency – and for our success,” according to Rüdiger Kaczka, Plant Manager at cpc.
By upgrading its ZSK twin screw extruders with the C-BEYOND platform, cpc has taken an important step towards increasing its overall production efficiency.
The heart of C-BEYOND is an all-encompassing data platform that enables valuable analysis of production processes. At any time, cpc can access all production data from its ZSK lines instantly and transparently. Customizable dashboards summarize all plant efficiency data and visualize it in reliable, user-friendly analytical diagrams. Key production indicators (KPIs) for each line, including availability, production quantity and product quality, are easily accessible at a glance. This enables the seamless operation of machines and allows for the identification of trends, which can be leveraged to implement optimization measures.
“In the past, we often pulled together various statistics, calculation tools and our years of experience in order to make production-related decisions. With C-BEYOND, we can access valid data in one place that gives us the certainty that we are on the right track,” Kaczka said enthusiastically.
Order planning: live view and downtime tracking for high efficiency
A look at production planning demonstrates how cpc integrates the C-BEYOND service platform into its workflow and profits from it. Especially in the case of frequent order changes, it is crucial for the entire plant’s efficiency that extruders do not stand idle unnecessarily, or are warmed up without producing anything. Using C-BEYOND, cpc can see precisely when an order will be finished on every one of the ZSK extruders, and can promptly initiate preparations for the following order, ensuring seamless transfers between tasks and full exploitation of every machine.
C-BEYOND automatically accounts for production interruptions due to recipe changes, maintenance tasks, or other operational downtimes, providing the operational personnel the option to add additional useful information via tablets installed at the extruder. This downtime tracking enables evaluations over longer time periods, which in turn can reveal informative trends, allowing for implementation of measures to increase efficiency in the future. The system continuously documents which order was produced on which extruder, making the production process visible in detail. This data is helpful for claim management and can be used to optimize subsequent orders.
In case of machine breakdown or deviations in the operating window, C-BEYOND can automatically notify management and operating personnel, enabling even faster reactions.
Sustain app: for less energy consumption
“We take our responsibility for humanity and the environment very seriously”, said Alexander Schleberger, Managing Director of cpc. “For that reason, we use the Sustain app with the energy monitoring function to capture precise real-time information about our extruders’ energy consumption and individual aggregates such as motors, feeders or barrels. On this basis, we identify components and processes that consume a lot of energy and implement data-supported optimization measures.”
If all production lines are integrated into the system, C-BEYOND can capture and monitor energy consumption across the entire facility. Inefficient equipment or even energy waste can be reduced to an absolute minimum so that valuable resources are used exclusively in a targeted manner and a strategic plan for optimal energy use is possible.
“We are supporting cpc by connecting the ZSK extruders to C-BEYOND in order to structure production processes and the machines’ capacity more transparently, increasing efficiency in operation. For us, cpc’s digitization initiative confirms the added value that C-BEYOND can offer. We are convinced that will be a groundbreaking tool in the long term, helping customers achieve increases in productivity and sustainability. It makes us very proud to be able to travel this path together with cpc, and we look forward to continuing our collaboration,” said Markus Schmudde, Head of Research & Development, Compounding & Extrusion at Coperion.
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