Case study: Polyram - MCT Germany GmbH
Retrofit of an extrusion plant from the 1980s
Results
Spare parts procurement is secured again, and plant safety has been restored. This has minimized the risk of unplanned long downtimes.
Through modernization and adaptation of the operating concept, this plant no longer operates as a standalone solution.
The plant has been upgraded to a high level of automation, now aligning with state-of-the-art standards and reducing operating times.
Industry
Location
Gohfelder Poststraße 56
32549 Bad Oeynhausen
Employees
29
Here's why RPC chose BSG
As a plant from the 1980s had several deficiencies, Polyram MCT opted for a retrofit.
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
Innovative PLC components and space-saving control cabinets
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 Additionally, the analog operation/monitoring of the plant has been replaced by an automated system.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.
