Results

The control cabinets were tailored to fit the available space, with all components optimized for efficient placement.

Finally, there is a reduced risk of downtime and a production process that is more resilient to failures.

Spare parts availability and improved equipment uptime have been restored.

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.

Industry

Manufacturing high-quality, application-specific plastic granules based on technical plastics

Location

Bada AG
Untere Strut 1
77815 Bühl (Baden)

Employees

< 100

"The machine availability is now ensured once again. Furthermore, we now have a control system that is tailored to our processes and needs. Previously, we had to adapt ourselves."
Martin Wunsch, Production Manager
"At BSG, I always reach competent contacts. Even if the person has never dealt with Bada before, I receive quick, good, and targeted responses."
Alain Guckert, Head of Maintenance
"We didn't just retrofit an extruder control system; we future-proofed a production line. While I may not know the procedural challenges that lie ahead, I am confident that we can implement their solutions with BSG and seamlessly integrate them into the line."
Knut Hofmann, Head of Process Engineering

Here's why Bada chose BSG

BSG and Bada have been business partners for over 20 years. In this project, a retrofit was carried out to modernize the facility and increase production efficiency. However, there were some challenges that needed to be overcome.

Not enough space for and within the control cabinets

The control cabinets are located directly adjacent to the equipment, resulting in limited space for both the cabinets themselves and the components within them.

Dusty production environment

Dust must not enter the control cabinets, as there is a risk of electrical failures, which can lead to production downtime.

Outdated frequency converter for the main drive

The availability of spare parts is limited, and production reliability is compromised.

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.

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.

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.

In summary ...

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.

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Retrofit of an extrusion line