Extrusion Process Control

The client required a control solution that would provide state-of-the-art controls for a new modular extrusion line and also be capable of being plugged into a Global Information Highway. For this requirement, the client consulted with Apex Controls Specialists. The Global Information Highway collects data from each extruder process around the world and compares the data for "Best in Class" product capability.

Any good control system requires thorough understanding of the total process. Apex Controls Specialists has over twenty-seven years of experience in Plastics compounding systems. It is essential to be skilled integrators of all phases of operations, from the raw material handling and feed streams to the disposition of the packaged product. ACS understands that the successful extrusion project requires far more than simply placing equipment on the factory floor. Each successful extrusion project involves fully integrating all processes and issues into a system that fits seamlessly into the client's business.

Apex Controls Specialists begins at the factory floor in building any new control system. These systems are designed with the Operator and the Maintenance teams in mind. It is important in each project to supply control systems that Operations can efficiently use and Maintenance has the proper and effective documentation to quickly resolve issues that may arise.

Process Visualization

Powerful, easy-to-use operator interface is the cornerstone to high operability. All systems should be controlled from one Human Machine Interface (HMI). The operator can quickly set up and visualize the process from a small number of common screens.

Each component that makes up the process is presented on the screen in a 2D-process flow. All auxiliary equipment drives and feed systems communicate via high-speed network. This provides the operator with timely and precise feedback from the process.

Feeder System Interface

Extrusion System Diagnostics

The following screen represents an ACS system Start-up Permissives page. Should the operator at system start-up experience difficulty, the problem is quickly identified and resolved using the automated diagnostics developed by ACS.

Shutdown Causation Alarms

The following screen represents the First-Out Alarm page. While the extruder is in production and a fault should occur, the first event that caused the extruder to fault will be represented on the screen and the issue quickly resolved.

Raw Material Feeders

All screens depict precisely the actual process on the factory floor, as shown in this raw material feed screen below.

Conclusion

Every ACS control system is based on second-to-none skills and experience in the area of plastics compounding systems. All programmable controls and software are field-proven for suitability in extrusion applications. All HMI visualizations are designed with easy navigation in mind, with simple and accurate diagnostics. To assist in quality assurance, special production reports are provided and on-line SPC functionality. Apex Controls Specialists prides itself on being the "Best in Class" in extruder controls. Many years of careful development have produced Operator and Maintenance friendly control systems for which we are recognized worldwide.