The customer, placed in the zone of Bergamo, is a big producer made of different typology resins (acrylic, vinyl, ureiche, fenoliche). C.Si.Co. he has realized the automation of all the departments; here the case of the department is introduced only resins ureiche.

The customer, placed in the zone of Bergamo, is a big producer made of different typology resins (acrylic, vinyl, ureiche, fenoliche). C.Si.Co. he has realized the automation of all the departments; here the case of the department is introduced only resins ureiche.

A system existing, established from various size reactors (from 5 to 30 ton), produces ureiche resins. The system management is manual, and the customer intends to install an automation system in order of:

• decrease the operating mistake incidence
• increase the productivity, reducing the dead times and the influence of the human factor
• improve the quality, decreasing the deviation from the optimum requirements of the product and minimizing the differences between different batches.

The ureiche resin production process is exothermic; that means that in the critical phase a control system breakdown is potentially able to create damages to the machinery and the environment. Therefore a safe system is required.

The system is based on a controller of superabounded type (DCS).

In compliance with the customer, one decides completely to use a product new and unknown in Italy.

This DCS has been identified by the research and develop C.Si.Co., and tested in the laboratories before proposing it to the market, as alternative to the most well-known systems, that C.Si.Co. he has already broadly applied (Siemens S7H, ABB, MTL). It links with the typical security of DCS, a system of especially efficient programming and costs lower than 50% with respect to the products normally used.

On the plan of the interaction by the operators, C.Si.Co. he has had since put time at point supervision systems completely based on personal computer, allowing this way to remove the expensive electromechanical control panels.

Besides have acquired a remarkable experience in many of the supervision software you have on the market (iFix, WinCC, Intouch, Movicon, Zenon to mention only some) C.Si.Co. has built in the time a series of bookshops and born for Windows supervision driver, consolidating them in by now more than 50 installations; thanks to this work, C.Si.Co. systems with client/server functionality realize supervision applications without the necessity of buying specific package licences, so considerably knocking down the costs you fix.

The customer accepts this solution, reaching this way a total pulling down of beyond 70% on the costs fix of the system, without renouncing none of the request functionalities, and with a look&feel decidedly winning.

Given the customer's restrictive requirements, the period of mass in service must be completed whithin two weeks, in the period of closing of the departments for the summer holidays.

To satisfy this demand, C.Si.Co. he realizes simulated broad tests of the total application, being able to place the system so in production in a single week. Treating he of a process batch, C.Si.Co. he proposes to the customer a management automated also of the process phase sequenziazione later, able to increase further the results.

Also here, C.Si.Co., thanks to the developments of its Windows native bookshop, is able to propose an effective but extremely economic MES solution, not musting turn to packages trade them from the remarkable licence costs.

The controller batch interfaces to the business managerial system, receiving the production orders from it and data becoming again productive.

Furthermore a raw material data base is managed, with messaggistica of warning for the throw of orders of supplying with sufficient advance. 

After a few months of production and arrangement, the customer declares that all the objectives have been reached.

Since the moment of the installation, operating mistakes have not been verified, therefore taking their number from the previous average of three to the month to zero any more, with an economic advantage due to the reduction of the losses of various thousands euro in the first six months.

The dead times have humbled themselves, because the variability due to the human factor has been completely removed. Operators now assume a control function, drastically reducing the times of manoeuvre and the effort. The system productivity is stable and constant also in the night turns and the week-ends.

Excellent the results also on the good quality front. If the 13% of the product was previously rejected by the customer for not production conformity in the first six operation months, this percent has reduced herself to 5%. It has been possible to verify that this was due to a not correct definition of the productive parameters by the process engineers, not to imperfections of the process led by the system.