Case study: Schuite & Schuite Druckfarben GmbH
Production automation from raw material intake to finished product loading
Results
Modern and uniform automation, along with rapid support via remote access and a 24-hour hotline, minimizes extended production downtimes.
The entire production facility now features a centralized control system with a uniform user interface, ensuring easy and intuitive operation.
Through the modernization of the control system, spare parts are now readily available, and plant safety has been enhanced.
All key machine data is captured: Optimization measures are based on well-founded and traceable data.
About Schuite & Schuite Druckfarben GmbH
The Schuite & Schuite Druckfarben GmbH is a renowned manufacturer and supplier of high-quality printing inks – specifically rotary offset printing inks – for the graphic industry. The company places great emphasis on quality and innovation, continuously investing in research and development to provide its customers with the latest technologies and products.
A special focus is placed on environmentally friendly solutions. Here, Schuite & Schuite emphasizes sustainable production processes and develops environmentally friendly inks that comply with strict environmental regulations while ensuring high print quality.
In addition to the high quality of its products, the company also distinguishes itself through its excellent customer service. The experienced team provides customers with expertise and advice, assisting them in selecting the appropriate ink solutions for their individual requirements. Schuite & Schuite places great emphasis on close collaboration with its customers to develop tailored solutions and build long-term partnerships.
Furthermore, the company primarily delivers to its customers using its own trucks and drivers. These are deployed throughout Europe to ensure that the products always arrive at customers' locations on time.
Industry
Location
Wolff-Knippenberg-Straße 1
99334 Amt Wachsenburg
OT Ichtershausen
Employees
That's why Schuite & Schuite chose BSG
To increase efficiency and productivity, automating production plants is a crucial step. That's why S&S turned to BSG. In 2017, automation began in a newly constructed second production hall with two extrusion lines, which was then expanded to include the loading and unloading equipment, storage containers, and conveyor technology. In 2020, the aging control system of the first production hall underwent a retrofit.
Outdated plant control - no support
The existing production facilities were rudimentarily automated, and the programmable logic controllers were discontinued, making support nearly impossible.
No uniform automation
The new and older production halls were not uniformly automated, resulting in different operating concepts, which unnecessarily complicated production.
Lack of reliability/spare parts
Due to the aging control components, spare parts were scarcely available, thereby compromising the production's reliability.
Outdated documentation concept - high risk of data loss
The analog documentation concept (data collection via paper) no longer met current standards and consumed too much time.
This was made possible by BSG together with Schuite & Schuite
Modernization
The process began in 2017 with the automation of two extrusion lines in a new hall and was subsequently expanded to almost all of the plant equipment. The goal was to optimize the entire process from truck unloading to truck loading using a unified automation concept.
The existing hall was rudimentarily automated, meaning that little to no support was possible. To establish uniform automation and a consistent operating concept, the older hall underwent a retrofit in 2020. This included the entire outdated system, including the extrusion line, conveyor technology, and control.
Another challenge was that the modernization had to be done in three stages. This was because only up to 8 - 10 days of production could be pre-planned, requiring downtime to be kept as short as possible.
Improvement of support: Restoration of spare parts procurement and reliability
Implementation of Datagate
Furthermore, the digitization of plant technology was advanced to enable faster access to crucial information. This has not only led to more transparent production processes but also facilitates the maintenance and upkeep of the plant and enables efficient fault analysis in case of disruptions or quality issues.
Another advantage of Datagate is the machine data acquisition with energy management queries. Energy consumption can be optimized, leading to cost reduction. Additionally, this allows for better planning of maintenance work. Continuous monitoring of the plant's condition enables more efficient planning of maintenance intervals and minimizes unplanned downtime.
In summary ...
The automation of the facility was a crucial step for Schuite & Schuite to remain competitive and continuously improve their production processes. Overall, the automation of the facility has led to a more efficient and reliable production, not only simplifying and enhancing the operation of the plant but also improving the quality of the products.
The uniform control stations ensure intuitive operation and facilitate the training of new employees. Additionally, Datagate supports Schuite & Schuite in better controlling and monitoring the entire production process. Real-time access to data allows for quick response to any deviations, enabling the early detection and resolution of potential issues before they impact product quality.