Case study: Bada AG
Retrofit of an extrusion line
About Bada AG
The Bada AG, headquartered in Bühl and founded in 1997, is dedicated to providing plastic solutions that meet the requirements of various industries. The company places great emphasis on utilizing high-quality materials and state-of-the-art technologies to ensure products of the highest quality.
Many of the compounds are custom solutions tailored to specific use cases. The challenge lies in producing the multitude of formulations and compounds with low production batch sizes, while remaining flexible, cost-effective, and delivering on time in the required quality.
The company continuously invests in the development of new technologies and materials to meet the ever-growing demands of the market.
Furthermore, its products undergo rigorous quality controls to ensure they meet the highest standards and to continuously improve product quality.
In its production processes, Bada AG prioritizes resource-efficient practices and materials to minimize its ecological footprint. Through recycling and reusing plastic waste, the company contributes to environmental conservation. Additionally, it develops energy-efficient solutions to decrease energy consumption.
Many of the compounds are custom solutions tailored to specific use cases. The challenge lies in producing the multitude of formulations and compounds with low production batch sizes, while remaining flexible, cost-effective, and delivering on time in the required quality.
The company continuously invests in the development of new technologies and materials to meet the ever-growing demands of the market.
Furthermore, its products undergo rigorous quality controls to ensure they meet the highest standards and to continuously improve product quality.
In its production processes, Bada AG prioritizes resource-efficient practices and materials to minimize its ecological footprint. Through recycling and reusing plastic waste, the company contributes to environmental conservation. Additionally, it develops energy-efficient solutions to decrease energy consumption.
Industry
Manufacturing high-quality, application-specific plastic granules based on technical plastics
Location
Bada AG
Untere Strut 1
77815 Bühl (Baden)
Untere Strut 1
77815 Bühl (Baden)
Employees
< 100
Here's why Bada chose BSG
This was made possible by BSG in collaboration with Bada
Optimal control cabinet construction
A major challenge was that the control cabinets were placed directly adjacent to the equipment, necessitating space-optimized construction. Additionally, due to the limited space within the cabinets, it was important to design them in a way that allowed the components to fit optimally.
Modified control cabinet climate control
Another challenge was the dusty production environment. Due to these conditions, conventional filter fans could not be used in the control cabinet doors.
Instead, a filterless control cabinet climate control system was implemented to ensure that no dust enters the cabinets. Additionally, Solid State Relays (SSRs) with heat exchangers were installed in the control cabinet doors to ensure efficient cooling.
Instead, a filterless control cabinet climate control system was implemented to ensure that no dust enters the cabinets. Additionally, Solid State Relays (SSRs) with heat exchangers were installed in the control cabinet doors to ensure efficient cooling.
Modernization of the frequency converter (FU) at the main drive.
The third challenge was that the main drive of the system was outdated, with scarce availability of spare parts. This led to compromised production reliability and increased downtime.
Hence, the frequency converter (FU) for the main drive was replaced to ensure reliable and long-term functionality as well as the availability of the system.
Hence, the frequency converter (FU) for the main drive was replaced to ensure reliable and long-term functionality as well as the availability of the system.
Analysis with ONEdatagate
ONEdatagate is a digital data recording system that enables seamless tracking and documentation of process data.
With ONEdatagate, Bada now has the capability to gain valuable insights into the performance of production through real-time data, allowing for analysis and optimization of processes.
With ONEdatagate, Bada now has the capability to gain valuable insights into the performance of production through real-time data, allowing for analysis and optimization of processes.
About Bada AG
Thanks to the collaboration between BSG and Bada, these challenges were successfully overcome. The retrofit project has contributed to modernizing the facility, increasing production efficiency, and restoring production reliability. The longstanding business partnership between BSG and Bada has once again proven to be successful. Another extruder retrofit is already being implemented together, and more projects will follow in the future.