Case study: Polymer-Chemie GmbH

Retrofit of an extrusion plant

Results

The extrusion line now complies with safety standards.

The automation components are state-of-the-art, ensuring short procurement times for spare parts.

The line now has a modern user-friendly operating concept, which is also installed on the other plants of the company.

About Polymer-Chemie GmbH

The Polymer-Chemie GmbH, based in Bad Sobernheim, Germany, specializes in the development and production of high-quality polymers. Through years of research and development, Polymer-Chemie GmbH has created a wide range of customized polymers that meet the requirements of various industries.

Since its founding in 1973, the company has earned an excellent reputation and is now a key player in the industry, employing around 500 workers and being one of the largest employers in the region.

A particular focus of the company is on the production of specialty polymers with outstanding properties. The company prides itself on supplying customers worldwide with customized polymer solutions, enabling them to optimize their products and gain competitive advantages.

The quality and reliability of Polymer-Chemie GmbH's products are the result of modern and efficient production practices. The company boasts state-of-the-art facilities and laboratory equipment, allowing for the production of polymers in large quantities while maintaining the highest quality standards. Additionally, environmentally friendly processes are prioritized during production to conserve resources and reduce emissions.

Industry

Development and production of high-quality polymers for various industries

Location

Am Gefach
55566 Bad Sobernheim

Employees

approximately 500

"Thanks to the long-standing collaborative partnership, the retrofit of the plant from planning to commissioning was very well executed by BSG, taking into account customer requirements. Due to the experienced staff, especially Mr. Klinke, the concept development and preliminary planning proceeded smoothly and without complications."
Jens Weyrich
Control technology & planning

Here's why Polymer-Chemie chose BSG

The extrusion plant dated back to the 1980s, a time when there were no machinery directives prescribing safety standards for equipment. Due to the age of the plant, the control system was outdated. Additionally, many electrical components, including the entire switchgear, were no longer available as new items. Therefore, the plant could only be put back into operation after the defective components were repaired and reinstalled. This led to long downtimes and resulted in significant production losses.

Outdated plant without safety shutdown

The plant did not comply with the Machinery Directive and corresponding safety standards.

Outdated switchgear

Many electrical components were no longer available, leading to long downtimes in case of failure.

Outdated control system (analog operation)

The entire plant was monitored and operated solely through an analog control system using outdated control panels.

This was made possible by BSG in collaboration with Polymer-Chemie

Concept development

After the client conducted a risk analysis, BSG performed a Sistema calculation and appropriately sized the safety-relevant electrical components.

Modernization of switchgear systems

As part of this, a new switchgear cabinet with state-of-the-art control components (S7 1500 CPU) was installed. As a result, the system now complies with the Machinery Directive, ensuring adherence to safety standards. Additionally, spare parts procurement is once again ensured, mitigating long downtimes due to extended repairs.

Modernization of the plant control system

The entire plant control system was automated, and the outdated control panel was replaced with a modern operator panel. During the setup of the operator panel, the customer-specific preferences regarding the user interface were also incorporated. With the control concept now being of the same type as in other Polymer-Chemie plants, quick and time-saving operator transitions between the plants are possible.

RFID-Login

The modernization also included an RFID login key system. With this system, operators can log in directly at the operator panel using a chip, enabling the company to manage users securely and save time. Additionally, manual changes are recorded, allowing for precise tracking and traceability.

ONEdatagate implementation

The extrusion line was also connected to ONEdatagate, like other systems at Polymer-Chemie. This allows for the recording of actual and target values, as well as monitoring parameters. This enables Polymer-Chemie to react quickly to deviations, maintain high product quality, and optimize plant performance.

In summary ...

These measures brought the plant up to current safety standards, enabling more efficient and secure operations.

When will you write your success story with us?

Get in touch with us