Returning a Roll Coater Paint Line to Maximum Profitability
Our automation engineers expanded line capabilities and upgraded to state-of-the-art Siemens digital drive systems to support a leading steel company.
Project: Bring Existing Automation Tech Back Up to Specs
A leading steel company hired E Tech Group to expand their line’s capabilities to begin production of light gage steel, as well as increase throughput on existing operations by upgrading an existing roll coater paint line to return it to the OEM specs of 1600 fpm.
Solution: Evaluate and Optimize the Automated Equipment’s Capabilities
To accomplish this, E Tech group conducted an equipment audit to determine the failure rate and root causes, and conducted a tension study to determine the equipment’s limitations. This data was then used to improve the tension control on the line by monitoring tower operations and load cell closed loop tension regulators, then tuning them accordingly.
Our engineers also analyzed cable conduit versus using remote I/O, performed a safety study and implemented the study’s recommendations, and performed startup and commissioning services of the plant.
Results: Unmatched Line Speed, Way Less Downtime
This successful project installed a state-of-the-art Siemens digital drive system with new PLC, operator stations, and HMI. The result was a 33% increase in line speed; the line was returned to the maximum OEM-spec speed of 1600 fpm from 1200 fpm prior to the upgrade. Another result of the upgrade was a 50% reduction in electrical downtime. With the hardware and software installation complete, E Tech Group expanded the line’s capabilities to include the production of light gage steel.
As one the nation’s leading control system integrators, E Tech Group is a multifaceted automation company offering the best in process automation solutions to manufacturers across industries. E Tech Group has experience in the metals, chemical, machine building/OEM, pharmaceutical industries, and more. Our turnkey factory integration services provide clients with robust, cutting-edge control systems that adapt, scale and optimize your processes.