HARMONIZER GOLD
Case History
ADVANTAGES
Availability improvement +3.5% Gain from baseline
+5.8%
ADVANTAGES
with PULSAR HARMONIZER + 544,000 rolls/month + 11,300 cases/month + 848 metric tons/year (*)
(*) Based on 130 gr./Roll
AFH 2500 $/ ton Consumer 3500 $/ ton
TOOLS FOR LINES MANAGEMENT Pulsar has developed and installed more than 150 basic versions and 40 Supervisors of REDS System Harmonizer Software It automatically regulates all the speeds of the machines without operator intervention on the line including the speed of the rewinder, the accumulator, the log-saw, the primary and secondary packaging and the palletizing. It sets up all the machines at the maximum possible speed.
BENEFIT • More production • More availability • Less maintenance • Less energy consumption of all machines
TOOLS FOR LINES MANAGEMENT Example of typical converting line composed by a rewinder and two packaging legs
TABLET
PC
COMPARISON OF 3 SOLUTIONS With different conveyors type Rewinder
•Rewinder 700 mpm •Logsaw 250 cut/min. •Wrapper •Bundler •Paletizer
Logsaw COMPARISON OF 3 SOLUTIONS WITH DIFFERENT CONVEYORS TYPE
Wrapper Bundler Palletizer
Belt
Chain Acetal
Chain ResiStill ®
SPEED MANAGEMENT MAIN CABINET ELECTRICAL CABINET OF EXISTENT OR NEW CONVEYOR PLC PULSAR SOFTWARE HARMONIZER PULSAR
According to the data collected in 80% of cases downtime is less than 8 minutes +2% ÷ 8% OF LINE AVAILABILITY ACHIEVED WORKING SPEED = MEAN SPEED = NO MORE STOP-AND-GO: REDUCED WEAR OF COMPONENTS - ENERGY SAVING - REDUCED SPEED RELATED “CRASHES” AND EVENTS
SINGLE LINE CASE HISTORY
CLIENT CONFIDENTIAL
Rew speed = 550 m/min Paper length = 30 m Rolls per log = 26
Speed = 477 roll/min = 18 log/min Weight = 130 gr.
Rolls per pack = 4 Wrapper min speed= 60 ppm Wrapper max speed= 160 ppm
Packs per case = 12
SINGLE LINE CASE HISTORY
CLIENT CONFIDENTIAL
Log accumulator capacity = 300 logs Shift duration = 8 hours Shift per week = 17 During an 8 hour shift, at every hour occurs a wrapper stop, duration 3 min*
* Avg. Data over 1 year data collection
Wrapper speed = rewinder speed Starting accumulator level = 50% No feedback on wrapper speed
STANDARD SITUATION
CLIENT CONFIDENTIAL
OEE LOSS = 3.5%* Production loss = 8000 rolls/shift
* Confidential Client Data over 1 year data collection
IMPROVED SITUATION
CLIENT CONFIDENTIAL
Wrapper speed = set automatically by PULSAR HARMONIZER based on rewinder speed + accumulator level Accumulator level SETPOINT = 10%*
* = more time to recover wrapper stops before stopping the rewinder
OEE LOSS = 0% (Downtimes due to machine availability and jumbo roll changeover are neglected)
Pulsar Engineering Srl Via Serenari, 29 40013 Castel Maggiore (BO) Italy C.F. e P.Iva 02642481200 Tel. +39 0516323011 Fax +39 0516323050 info@pulsarengineering.com www.pulsarengineering.com
Pulsar America Inc. 975 Parkview Rd (Suite 15) Green Bay, WI 54304 Phone +1 (920) 425 4078 Fax +1 (920) 221 0076 info@pulsaramerica.com www.pulsaramerica.com
Pulsar Shanghai Address 2F, Building #11 No. 988 Zhongchun Road Minhang District, Shanghai, Cina Tel: +86 21 60933799 Fax: +86 21 60933736 Mobile: +86 13818391101 info@pulsarshanghai.cn www.pulsarshanghai.cn