German mechanical engineering company Hosokawa Alpine presents practical solutions for system automation and digitalization that enable customers to operate their blown film lines more efficiently, safely and economically. A digital start-up assistant supports fast and error-free start-up, modern monitoring solutions ensure full transparency during operation and predictive maintenance tools help to avoid unplanned downtimes. This gives customers more planning security, reduces downtimes and increases the overall performance of their production.Â
Assistance systems make system operation easier
The heart of system automation at Hosokawa Alpine is the ExVis process visualisation software. Among other things, it includes a start up assistant that makes it easier to start up the system. The settings for a film formulation are stored in the software. This information allows operators to start up the system in four automated steps without having process engineering know-how themselves. The company offers an operating device for the film take-off, which can be connected to the take-off or the collapsing system and operated on site. This gives the operator immediate access to the connected component.Â
Automation solutions increase efficiency and productivity Hosokawa Alpine also supports blown film manufacturers with various automation solutions to optimize the use of their systems, speed up processes and measurably increase productivity. This includes an automatically adjustable cooling ring insert. Here, the optimum setting for the cooling air supply can be saved and automatically re-started.Â
The one-touch change included in ExVis includes preset format changes and reproducible settings for the collapsing system and side gussets. The software package thus enables accelerated start-up of a film format and fast switching between different formats. This minimizes changeover times and the associated material losses and offers film manufacturers a high degree of flexibility.Â
Monitoring systems for smooth production
In order to keep the productivity of the systems as high as possible, Hosokawa Alpine provides a system monitoring system that immediately visualises malfunctions in operation and production and enables them to be rectified quickly. A camera system with various cameras on the take-off, winder and MDO produces images that can then be called up via the operator terminal. This enables an overview from the control panel, even in areas of the system that are not visible.Â
In an emergency, the remote service from Hosokawa Alpine Blueserv, the company’s service brand, can quickly access the system.Â
Predictive maintenance with isa.guard
With the predictive maintenance tool isa.guard from Blueserv, maintenance requirements can be precisely predicted – for maximum system availability and an extended service life. “Problems are recognised before they become critical or even arise. This allows customers to plan interventions proactively and maximise the uptime of their systems,” explains Christian Hoffmann, director Blueserv Blown Film Extrusion. He adds with a wink: “With isa.guard, we have developed a kind of crystal ball that allows us to look into the future.”Â
By analysing a wide range of data and sensors, isa.guard provides a real-time diagnosis of the machine’s condition. This gives customers full transparency about their blown film production – around the clock.Â
In addition, concrete proposals for action are provided that enable a targeted and efficient response in good time.Â
The modular software platform isa.io enables a comparative analysis of process data to optimize performance and increase efficiency across all machines. “This gives our customers an excellent overview of all Alpine blown film lines – including the option of carrying out targeted deep dives for detailed analyses. Push notifications and many other functions can also be customized on request,” explains Christian Hoffmann.
