glass-worldwide-2013

technology > process control

Automation technology innovations Moreno Destro describes some of the latest automation systems that help the international glass container industry to optimise productivity, safety, emission control and energy saving.

T

he glass packaging industry has always led the way in automation technologies.

Processing this type of high performance, ecological and modern material requires advanced technologies that are precise and reliable.

Over the year, automation has been used to optimise productivity, safety, emission control and energy saving, obtaining higher and faster returns on investment. These important results have been realised thanks to the contribution of such companies as MCR Systems (part of the BDF Industries group) who, via its innovations, has radically transformed the industry.

Thanks to factory automation, extending from batch houses to furnaces, working ends to forehearths, cold ends to warehouses, utilities to automation buildings and to the integration of the entire system, glass factories can increase the quantity and quality of their production by managing information from various operations.

In fact, it is possible to control processing and monitor parameters in real-time by using state-of-the-art instruments to measure physical quantities and suitable final regulation elements. In addition, advanced computer vision techniques achieve precise and reliable measurements in hostile environments such as glass furnaces. An example is the innovative EAGLE (Enhanced Absolute Glass Level) system, which measures glass levels using optical reflections coming from a pointer not in contact with the glass and which was designed and patented by MCR Systems. This is an extremely useful device that helps maintain correct levels in the processing area.

SYSTEM INTERACTION Once collected, information is sent to the control system, the heart of the

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EAGLE supervision page example.

glassmaking process.

Operators can interact with the whole production system using simple interfaces, located directly at their local HMI posts.

The main supervision devices used by operators are redundant SCADA server PCs, to which client PCs and/ or operator panels are connected.

The structure to access data is significant, as well as safe and based on different levels of access, is protected by passwords and organised according to CFR21p11 regulations on request. This is a standard for demanding markets in terms of security, eg the pharmaceutical sector.

The control structure is based on redundant components such as PLCs with CPUs, power supplies and remote I/O modules connected to CPUs via a field bus.

Redundancy is essential for this

Glass Worldwide > issue forty seven 2013

type of process, as it runs 24h/day, 365 days/year and never stops during the operational life of the system, which usually varies from six to ten years or more. This solution also enables economies of scale for cableways, signal cables and power cables.

In turn, acquired data is sent to the ERP (Enterprise Resource Planning) via MES (Manufacturing Execution Systems) software applications, which elaborate and send them to plant controllers. Complete accessibility to data means that this type of approach is extremely safe and

Glass level EAGLE.

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technology > process control easy to use, as operators as well as management can modify the system by optimising productivity, efficiency and investment yields.

FUTURE CHALLENGES The implementation of automation technologies and efficient integrated systems enables the glass industry to face future challenges posed by the global economy. The European Union’s 20:20:20 package sets a target of 20% less emissions by 2020, which in turn means that this sector needs to take advantage of energy saving strategies. This is essential not only economically, in order to be competitive but it is also important at a social and environmental level.

The situation is not easy, as energy consumption is a major problem. In fact, glass requires furnaces with temperatures reaching 1600°C which, of course, need a lot of energy. Nonetheless, producers are facing the challenge and are investing in up-to-date technologies and improving cost containment.

To date, consumption has been optimised using sophisticated technologies to monitor energy consumption, as well as technologies providing actual savings. Systems for the acquisition of information on electricity, gas and compressed air have proven particularly effective and are available for PC networks (even remote ones) or for process control networks.

There are also innovations involving energy savings relating to warehouse lighting as usually, high power lamps are switched on all year round. Energy savings can be provided that generally represent 5% of the total energy used by the plant. To obtain rational savings

Batch charger supervision page example.

without affecting lighting efficiency, technologies have been developed that use special thrystor luminous flux regulators derived from booster plants, which can reduce electrical consumption by up to 30%, without modifying the characteristics of the plant.

Finally, research and production, together with sustainability policies, are trying to achieve an active role in the development of a low emission economy, as required by the European Union (a 2050 objective).

The use of fossil fuels for furnaces alongside carbon released during processing are the main reasons for CO2 emissions in the glass manufacturing industry.

Unfortunately, it is difficult to

eliminate such problems, as glass cannot be made any other way, no matter how much the use of recycled cullet is promoted. Nonetheless, significant efforts are being made for the creation of reduced polluting emission plants. Take for example the systems for the continuous monitoring of emissions (CMEs) that prevent and reduce air pollution during the various production phases. Not only are they innovative and reliable but they are also equipped with the most advanced and complex data and analysis exchange software. This is an ideal solution to help plants comply with the strictest regulations concerning environmental protection.

Batch charger electrics cabinet.

Glass level EAGLE.

ABOUT THE AUTHOR: Moreno Destro is Sales Manager at the MCR Systems subsidiary of the BDF Industries group FURTHER INFORMATION: BDF Industries SpA – MCR Systems, Genoa, Italy tel: +39 010 31 50 07 email: m.destro@mcrsrl.it web: www.bdf.it / www.mcrsrl.it

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Glass Worldwide > issue forty seven 2013

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