Blending Products. Product Updates / Alan Landers

Transcription

1 Blending Products Product Updates / Alan Landers

2 Model SB-3 SmartBlend Control Full 7-inch color graphics aid usability. Display simultaneously shows all material positions and settings. Selectable for either four or six position. Option for up to 12 positions.

3 Model SB-3 SmartBlend Control Recipes: Create and assign easy-to-recall recipes. SmartBlend SB3 software provides local recipe and material naming storage: Up to 3000 recipes Up to 4000 materials Alpha-numeric IDs allow up to eight (8) characters.

4 Model SB-3 SmartBlend Control Alarm storage and recall: Alarms are meaningful, helpful messages to keep the blending operation running trouble-free. SmartBlend software tracks up to 100 events and reports alarm date, time and error type. Alarms are set according to user-defined parameters.

5 Model SB-3 SmartBlend Control Integrated conveying control: Conveying screen (optional) sets parameters and controls up to twelve (12) loaders and (1) pump per blender. Includes priority loading Interconnect multiple blenders, pumps and associated standard receivers as an optional configuration. Provides commonality of blender and loading controls, simplifying operator training and know-how.

6 Model SB-3 SmartBlend Mixer New Design Sealed chassis prevents pellet leakage. Ensures weighed pellets pass into the process, not onto the floor. Enclosed design holds three (3) batches and eliminates pellets leaking from the unit and tossed around in the blender.

7 Model SB-3 SmartBlend Mixer Old Design New Design Old Design

8 Model SB-3 SmartBlend Reporting USB Stick Windows Based PC Ethernet Cable

9 Model SB-3 SmartBlend Reporting Alarm Reports: Provides a list of active alarms, or alarms that are inactive but have never been acknowledged. The report includes a description of each alarm, date and time of the alarm and whether it has been acknowledged. Another report provides a history of the last 500 alarm events in the system. Alarm Log Report Production Line: Line 1 System: TW Blender Mon Feb 4 23:44: Time Ack State Alarm :12:07 na 1 System - Information Alarm 03:12:07 na 1 Central Hopper - Hopper low on material

10 Model SB-3 SmartBlend Reporting Inventory Reports: Provides the total material usage by the system, including both total and individual ingredient throughputs. Material usage can also be reported by 3 shifts. Shift Report Production Line: Line 1 System: TrueBlend Sat Dec 8 08:50: Total Percent System(Lbs) Batches 324. Component 1(Lbs) Component 2(Lbs) Inventory Report Production Line: Line 1 System: TrueBlend Sat Dec 8 08:51: Total Percent System(Lbs) Batches 326. Component 1(Lbs) Component 2(Lbs)

11 Model SB-3 SmartBlend Reporting Resin and Orders Reports: Consumption data for each of up to 4000 resins and consumption for a particular order/job.. Orders Report Resin Report Production Line: Line 1 System: TrueBlend Wed Dec 5 18:33: ID Resin Name Density Inventory Resin Resin Resin Resin Production Line: Line 1 System: TrueBlend Sat Dec 8 08:51: Order Name: cups red Total Percent System(Lbs) Component 1(Lbs) Component 2(Lbs) Component 3(Lbs) Component 4(Lbs)

12 Model SB-3 SmartBlend Reporting Batch Diagnostic Data: Dosing data log for each batch made.

13 Model SB-3 SmartBlend Reporting What Can SQL do? SQL can execute queries against a database Queries of individual or all blenders Alarms, Resin Totals, Job Totals, Recipe Totals, SQL Express Batch Diagnostics Network hub

14 Model SB-3 SmartBlend Remote Communication Virtual Network Client Viewer Remote control of all your blender parameters from a central PC (supplied by customer). Multiple blenders can be monitored / controlled from a central PC (supplied by customer). Anything you can do on the local touch screen, you can do on the VNC using a mouse. Microsoft Windows compatible

15 Model SB-3 SmartBlend Remote Communication Ethernet is a hardware system for connecting computer systems to form a local area network, with protocols to control the passing of information and to avoid simultaneous transmission by two or more systems PC or PLC with Protocols Network hub

16 Model SB-3 SmartBlend Remote Communication Protocol is a set of rules or procedures for transmitting data between electronic devices, such as computers. PC or PLC with a Protocol Network hub

17 Model SB-3 SmartBlend Remote Communication Modbus is a protocol originally published by Modicon in 1979 for use with its PLCs. It has since become a standard protocol and is now a commonly available means of connecting industrial electronic devices. PC or PLC with Modbus Protocol Network hub

18 Model SB-3 SmartBlend Remote Communication EtherNet/IP is an application layer protocol which means it is simply the way data is organized in a data transfer packet. PC or PLC with EtherNet IP Protocol Network hub

19 Model SB-3 SmartBlend Remote Communication OPC UA protocol is based on a crossplatform, which expands on the security and functionality found in OPC Classic instead of the Microsoft-based COM/DCOM technology. PC with OPC Protocol Network hub

20 Model SB-3 SmartBlend Remote Communication A customer says they want Ethernet capability. You say What protocol, Modbus, Ethernet IP or OPC UA? PC with Protocol Network hub

21 Batch Blender Comparison Conair Maguire Touchscreen Standard Optional Modbus/Ethernet Standard Optional Ethernet IP Optional NA OPC UA Optional NA VNC Viewer Optional NA Batch Logging Standard Optional Reports Standard Optional SQL Reporting Optional NA Leak Free Design Standard NA Self Loading Optional 5 Blenders Optional 1 Blender PLC Electronics B&R/ABB Proprietary

22 Model SB-3 SmartBlend SB1 to SB3 Upgrade New 7-inch Touchscreen New Electrical panel New Pneumatic Valves High Reliability Approx $4,900

23 Model SB-3 SmartBlend SB1 to SB3 Upgrade Touchscreen: 7-inch touchscreen very responsive to the operator touch. SB1 has 5.7-inch screen. Dosing: SB3 has direct to target dosing so all components are treated as precision ingredients, whereas SB1 had only one precision ingredient dosing capability. Remote Communications: SB3 has Modbus TCP, Ethernet IP, OPCUA, and VNC Viewer. SB1 has Modbus TCP. Batch Data Logging: SB3 has ability to log batch historical data directly to a file on a PC or a USB Stick. SB1 requires Windows based reporting software.

24 Model SB-3 SmartBlend SB1 to SB3 Upgrade Reports of Resin Totals: SB3 will report resin usage data to a file on a PC or a USB Stick. SB3 can store 4000 resin names and 3000 recipe names for this purpose. SB1 stores 100 recipes. SQL Reporting Capability: SB3 has the ability to collect each blender s batch, resin usage by name, recipe and generate consolidated summary reports of this information across all blenders on the system. Self-Loading Capability: SB3 has the ability to control vacuum loaders on 5 blenders and up to 1 pump per blender. SB1 controls loading on 1 blender with 1 pump. PLC Electronics: SB3 uses B&R/ABB highly reliable electronics. SB1 uses a combination of Wago and proprietary electronics.

25 Stabilizing output Weight throughput control and length throughput control (synchronized control) Controls grams/meter, full automatic control of extruder and puller ΔW / ΔT Loss-in-Weight Nip / Puller Extruder Drive Speed (+/-) = Data Haul-off Drive Speed (+/-) = Control

26 Layer ratio Multiple extruders Educated guesswork Varying skill sets Process variables Hit or miss repeatability Wide tolerances Vs. Computer control

27 Tighter tolerances Running closer to minimum specification minimum OD +/ Wall tolerance: Min Nominal Size Outside Diameter Wall Thickness Average Tolerance Minimum Tolerance ± $$$

28 Tighter tolerances 2" PE 2708 Gas Pressure Pipe IPS DR11 Specific gravity Cost/Lb OD (fixed) Wall Tolerance ID Extrusion rate (lb/hr) Annual production hrs Line speed (fpm) Annual throughput (lb) 10,753,740 11,199,483 11,640,615 Give away (lb) 445, ,875 Linear feet 17,640,000 17,640,000 17,640,000 Annual material cost $ 9,033,142 $ 9,407,566 $ 9,778,117 Give away ($) $ 374,424 $ 744,975 $ 370,551

29 TrueWeigh Extrusion Control w/ Gauge Interface Control Extruder Rate Control Puller Rate Extrusion Application No competitor

30 Screw Rate Monitor or Control with TrueFeed Monitor Extruder Rate Control Additive Rate Extrusion Application No competitor, available Qtr 2, 2018 TrueWeigh Hopper TrueFeed ΔW / ΔT Loss-in-Weight

31 TrueBlend/ TrueBlend EXT with TrueFeed TrueBlend Blender Control Additive Rate Injection or Extrusion Application Not offered by competitors Available Qtr 2, 2018 TrueBlend TrueFeed

32 ScrapSaver TM In-line thin film reclaim systems

33 ScrapSaver TM Ideal for scrap bulk densities from 3-20 lbs/cu.ft Accommodates 100% of the trim scrap (up to ~25% of production). If fluff runs out, pellets will make up the difference. ScrapSaver follows the extruder drive speed to protect against over/under feeding.

34 ScrapSaver TM Note on throughput variability: Maximum scrap refeed rates will vary with: extruder feed section shape & area extruder screw design and feed channel depth overall product s scrap tolerance (how much can be added without surging). A proper balance will allow steadystate running without surging.

35 NPE Blending Equipment

36 NPE Equipment Medline TrueBlend TB45 Medline TrueBlend Batch Blender Calibrated to ISO standards The MedLine TB45 is calibrated to ISO standards, perfect for any cleanroom application. The touch screen is chemical resistant, and easily cleaned by isopropyl alcohol. The RAL 9003 paint maintains the clean bright look you would expect in a cleanroom.

37 NPE Equipment TrueBlend TB500 TrueBlend Batch Blender Leak-free easily removable mixer 7-inch Graphic Touchscreen Control In simulation mode to show operation

38 NPE Equipment TrueFeed Touch Control TrueFeed with Touchscreen Quick clean easily removable hopper 8-inch Graphic Touchscreen Control

39 TrueFeed Additive Feeder Summary of main difference between: The Maguire MGF and Conair True-feed

40 NPE Equipment BFS Volumetric Feeder BFS Feeder Quick clean easily removable hopper Interchangeable Augers Throughputs up to 160 lb/hr

41 NPE Equipment Extrusion Blender TrueWeigh Continuous Blender Metering rates up to 3000 pph and down to.25 pph with central weigh hopper Metering rates to 18,000 pph with central tube (no weigh hopper) Precision extrusion applications Reclaim applications Compounding applications

42 Questions?

43 Thank You!