Digitalization of the Wet Grinding Process for Maximum Efficiency

Summary

In recent years, as competition in the paints sector has intensified, manufacturers have begun spending much of their time conducting research for better productivity and quality. However, perfect research cannot be conducted without having a good historical record of current production. Beyond this, in today's age of experiencing the fourth industrial revolution, all manufacturers must adapt to Industry 4.0 at some point. All of this requires digitalization of wet grinding, one of the main processes in facilities.

1. Introduction

Wet grinding is a challenging process! Machines are now operating with the smallest beads possible, at high flow rates and maximum power, with the highest capacity possible. For sustainable high performance, automation solutions must provide high process control and continuous monitoring of important process parameters.

2. SmartPro

SmartPro™ is the digital solution Bühler brings to the wet grinding process for high traceability, better process control and benchmarking. As a result, significant optimization is achieved in production. Bühler's five development stages foreseen for this system are shown in Figure 1 as follows.

2.1. Intelligent Automation

Premium and Premium Plus control systems represent the first stage of Bühler's digitalization. (Figure 2) It is a first-class solution consisting of PLC and touchscreen. It offers an easy and user-friendly new user interface through PLC programming and touchscreen. It diagnoses and provides information about machine status through work order analysis and operating data. Benefits for industry: 1. User-friendly design for maximum productivity. User-friendly design and user guidance facilitate proper operation of the machine. Control is easy and eliminates the need for extensive training. Additionally, thanks to its easy-to-read screen, color coding can be applied for alerts and stoppages. 2. Optimal product and machine management for maximum profitability. With Bühler control systems, all features of the machine can be utilized. Through the intelligent cockpit view, current process parameters including the optimal operating range can be examined. It has tools that enable rapid and accurate machine startup. 3. Supporting features for high process reliability. The integrated recipe assistant adjusts process parameters according to changing product characteristics. As a result, higher process reliability is achieved in a shorter time. 4. Modern data management for quality assurance. The control system uses intelligent data management for quality assurance and optimization. Users can access the past 200 work orders, ensuring product traceability and repeatability. Additionally, faults occurring for preventive maintenance of the machine are tracked and classified. Thus, machine maintenance intervals can be easily determined. 5. Remote access for easy process monitoring. With the Premium Plus solution, remote access to the control system is possible. This makes process monitoring much easier. Stoppages are detected faster and problems can be solved without being on-site. While this reduces costs, it increases productivity. When necessary, Bühler Customer Service provides fast and cost-effective service by accessing the machine remotely.

2.2. Intelligent Visualization

The goal of intelligent visualization is to make machine data accessible to you everywhere and at all times. Operators and even top management can access the machine's current values and historical parameters from tablets and/or mobile phones. Moreover, remote access and control are possible depending on user permissions. Users can set certain alarm values and request to be notified via SMS and/or email when these values are exceeded. A screenshot of the SmartPro cockpit can be examined in Figure 3.

2.3. Intelligent Statistics

You can analyze your machine data and use it to optimize the production process. Just as you adjust your pace when exercising using your smartwatch. At this stage, long-term statistics, internal and industrial benchmarking capabilities and external data export will be possible.

2.4. Intelligent Machines & Facilities

At this stage, machines and even facilities will be connected to each other via the cloud. Machines will continuously monitor their own parameters and optimize process parameters and production.

3. Conclusion

You must trust your processes. They must deliver seamless operation and address numerous needs such as maximum product safety, energy efficiency and easy operation. As a solution partner with years of experience in automation, Bühler sets industry standards and delivers the highest possible quality. Benefits of all this digitalization for industry: 1. High productivity, a. High order readiness, b. Short reaction time for maintenance, 2. Low costs, a. Reduction in unnecessary maintenance visits, b. Decrease in external maintenance costs, 3. Quality assurance, a. Production traceability & documentation, b. Fewer product quality complaints from customers, 4. Process safety, a. Prediction of potential failures, b. Early detection of anomalies.