Compressed air is a key component of today’s factory production. Because massive, power-demanding compressors are required to keep this key resource flowing it is important for factories to carefully manage how they use it—and to prevent leaks that could waste significant amounts of power.
Take for example a plant that combines the stretch blow molding (SBM) process for making plastic bottles with bottling in a single location. This provides great efficiencies while demanding a lot of pneumatics, both for blowing/bottling and for operating valves and machinery.
For years compressors and the SBM process only had two settings: fully off and fully on. This led to too many bottles being rejected due to being misformed by the “dumb” process. New “smart” machines use IIoT to gauge the required flow rate to maximize production, especially important to create bottles of varying sizes and thicknesses throughout the day.
Using Zedi SaaS SCADA™ to manage the data collected by sensors at key points along the pneumatic system, the manufacturer has been able to monitor changes in air flow at those points. This allows them to quickly detect leaks, giving them two advantages: timely repairs and early warning for systems that need preventive maintenance. Cloud based data also gives them analyzed, actionable data on the SBM system itself, warning of PM needs and other adjustments.
It tracks and stores data on every bottle blow, allowing for further adjustments leading to even more efficiencies and savings—every day.
This data is available in exactly the format the company needs. On the cloud, it is there for the right personnel at the right time, wherever they are. Authorized users can set alarms that also give appropriate level warnings. These alarms can be set with varying levels of urgency and go to client-set staff levels.
The system’s success lies in three main areas: increased uptime, more efficient energy use due to fewer leaks, and more efficient production with fewer lost bottles. It also reduced heating temperature in the pre-heating ovens involved in preparing the plastic for blowing. Less bottle waste also means reduced costs for plastic raw materials because more of it is used productively.
Hopefully you’re seeing that the factory of the future is arriving on your doorstep right now. Emerson is driving innovation that is helping industries around the globe become healthier, safer, smarter and more sustainable every day. Zedi SaaS brings you the right data you need, anytime, anywhere.
