Case study: Polyram - MCT Germany GmbH

Retrofit of an extrusion plant from the 1980s

Result 1

Spare parts procurement is secured again, and plant safety has been restored. This has minimized the risk of unplanned long downtimes.

Result 2

Through modernization and adaptation of the operating concept, this plant no longer operates as a standalone solution.

Result 3

The plant has been upgraded to a high level of automation, now aligning with state-of-the-art standards and reducing operating times.

About Polyram - MCT Germany GmbH

Polyram - MCT Germany GmbH, founded in 1980 and based in Bad Oeynhausen, manufactures high-quality plastics.

The product range of Polyram MCT is extensive and includes a variety of engineering plastics, compounds, and masterbatches. These are used in various industries, including automotive, electronics, medical technology, and construction. The company has state-of-the-art production facilities, allowing for the development of tailored solutions to meet the individual requirements of customers.

A key element of Polyram MCT's success is its commitment to research and development. The company continuously invests in its research and development department to develop new materials and enhance existing products. This approach has enabled the company to develop a range of patented technologies.

Furthermore, Polyram MCT places great emphasis on sustainability. The company is committed to developing environmentally friendly products.

Industry

Manufacturer of application-optimized polypropylene compounds and thermoplastic elastomers.

Location

Polyram – MCT Germany GmbH
Gohfelder Poststraße 56
32549 Bad Oeynhausen

Employees

29

"BSG is a long-standing business partner at our side. Service is a top priority here, no matter how small or large the task. Thanks, especially to Mr. Klinke, for the good and productive cooperation."
Thorsten Burstedt, Geschäftsleiter

Here's why RPC chose BSG

No spare parts - plant safety compromised

The main concern was the lack of spare parts for the plant, posing a risk to plant safety and resulting in unplanned downtime.

Isolated solution regarding the operating concept.

Since the plant was still equipped with third-party control panels and a different operating concept, this made it difficult for operators to transition to the unified operating concept of the other plants.

Analog operation with high time expenditure

The plant was still operated and monitored in an analog manner, requiring temperature zones to be manually adjusted using controllers and switches, which was time-consuming.

This was made possible by BSG in collaboration with Polyram MCT

Partnership since 1995

Polyram-MCT was one of the first clients of BSG. The initial collaboration dates back to 1995 (the founding year of BSG). During the long and successful partnership between BSG and Polyram-MCT, almost all plants at Polyram-MCT have undergone a retrofit by BSG. In previous retrofit projects, primarily the PLC components were replaced, and new control panels, as well as modern control systems, were installed.

Innovative PLC components and space-saving control cabinets

As part of the project, this plant was upgraded to a high level of automation. The latest PLC components along with a modern control system, new control panels, and new control cabinets were supplied and installed by BSG.

A particular challenge in delivering new control cabinets was the limited space available, as the cabinets were previously smaller and contained fewer components.

The plant is now exclusively controlled using a single control panel, with no third-party panels in use. Additionally, the analog operation/monitoring of the plant has been replaced by an automated system.

In summary ...

Overall, the retrofit project was a great success for BSG and Polyram MCT. The upgrade to a high level of automation has not only improved the efficiency of the plant but also restored spare parts procurement and thus plant safety, minimizing the risk of unplanned downtime.

The staff can now be deployed more effectively. All plants now have the same operating concept, making it easier for operators to transition to or from this plant. Through the modernization, the plant is now state-of-the-art and complies with the latest standards.

The successful collaboration between Polyram MCT and BSG has demonstrated that retrofit measures can bring older plants up to the latest technological standards.

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