What was done ...

With its new extrusion line, Klever Kunststoff Recycling GmbH is investing in future-proof technology. On behalf of KKR, BSG implemented a modern solution that perfectly combines process reliability, efficiency, and digital transparency.

KKR GmbH is taking the next step toward digitalization and efficiency: Together with BSG, the first extrusion line was successfully automated and equipped with the ONEdatagate data acquisition system.

As part of a detailed consultation and joint analysis, an optimal, tailor-made automation concept was developed, including the ONEexchange digital platform with the ONEdatagate data acquisition solution.

After receiving the order from KKR GmbH, BSG took over the complete control equipment for the plant with modern PLC and HMI hardware. The software was customized and precisely tailored to the processes of the extrusion line. This also included the conveyor technology with silos and dosing scales. These components were also integrated into the control system to ensure a continuous, efficient material flow.

A special feature of the new line is the batch process, in which several raw materials are homogenized in a separate process – flexibly, reproducibly, and with full process data transparency via ONEdatagate.

KKR GmbH thus benefits from a future-proof solution that precisely meets its requirements. Advantages of full automation for KKR:

• Less manual work for greater process reliability
  Machine operators benefit from automatically controlled and monitored processes. This reduces sources of error, relieves the burden on employees, and ensures consistently stable production processes.
• Full transparency in real time
  All relevant process data for the entire line, including the batch process, is digitally recorded, visualized, and centrally evaluated. Production managers receive a precise overview of current performance indicators and quality parameters at all times. This enables them to react more quickly, analyze causes, and make informed decisions—with complete traceability for every batch.
• Higher product quality through controlled homogenization
  Multiple raw materials are precisely dosed, mixed, and digitally documented. The result: consistently high product quality, less waste, and lower material losses.
• Future-proof technology instead of isolated solutions
  The new automation solution has a modular design and can be seamlessly integrated into existing IT and production systems. KKR is thus creating a sustainable basis for future expansions, further automation steps, and the expansion of digital services. This keeps production flexible, scalable, and well equipped for future requirements.

With over 30 years of experience in the automation and digitalization of plastics production plants, BSG is one of the recognized specialists in the industry. The project at KKR once again demonstrates how BSG implements customer-specific automation solutions in a practical and innovative manner—from consulting to commissioning.