ELVIprUP

Description

ELVIPLAS S.A. is a producer of flexible plastics to be used for packaging, both for households and industry.

ElVIprUP is an ICT investment project for the digitalization and automation (adoption of Industry 4.0 principles) of a plastic blown film production plant, aiming to reduce the correction time and quality failure, resulting in capacity increase and cost reduction.

SIRMET S.A. will be their partner. It is an engineering company with expertise in wastewater management technology. They will contribute with consultancy on the environmental aspects of ELVIprUP, and develop the proprietary software and algorithms that will be used to monitor and optimize the production process.

The implementation of the project will help the Project Promoter to solve the problem of producing lower quality products due to machine failures, and will lead to a reduction of defective batches, which are not used and are by-products of the industry. Altogether, it will enhance the competitiveness of ELVIPLAS S.A, as well as their revenues, and result in a reduction of emissions from their production.  

Summary of project results

The project concerns the upgrade of ELVIPLAS S.A. plastic blown film production plant, by optimizing its process line and incorporating a system for the automatic monitoring and control of parameters that affect the properties of the final products. 

The project included the following activities:

Requirements analysis and solution design

Analysis of the requirements and designing a solution that would accurately represent and improve Elviplas S.A.''s production processes. Firstly, the right way to accurately describe each stage in the production workflow was identified. In addition, the detailed technological requirements and the hardware specifications necessary for the implementation of the monitoring system were identified. Key considerations included:

• The specifications and scalability,
• Hardware compatibility,
• The quantity and type of training and verification data needed to ensure accurate predictions, and
• Adaptability to process variations and real-time adjustments.

An initial analysis of collected data guided the preliminary design approach, enabling a solution that can predict (through automation) potential malfunctions and adjust to fluctuations in production. This predictive capability is essential for handling variations within the manufacturing process, allowing the solution to detect and respond to changes as they occur in real time.

Through this detailed requirement analysis and solution design, Elviplas S.A. identified the necessary equipment, sensing systems, and hardware needed to align with the goals of effective process modeling. This strategic approach enabled the company to make informed purchases, ensuring all components are well-suited to support enhanced process.

Solution implementation

In this phase, the project team utilised collected input-output data to accurately represent real-world operations. The result was the definition of critical process parameters to ensure the output (product quality) remains within the specified standards. Key quality indicators included film thickness, width, and planarity of the blown film, all of which needed to stay within defined tolerances.

For optimization, various parameters were tested based on the final target values to achieve optimal process conditions. Alongside this, data management and visualization applications were developed, allowing for the integration between the modeling software and the SCADA (Supervisory Control and Data Acquisition) system. This interface enables the display of predictive modeling outcomes through real-time graphs, enhancing data accessibility and clarity for operators.

With the modeling and visualization framework established, Elviplas S.A. moved forward with finalizing the procurement of essential new equipment. This included sensors, controllers, flow meters, and the SCADA system itself, ensuring the company’s infrastructure fully supported the advanced process monitoring and optimization objectives.

Testing and evaluation

Each piece of equipment was ordered with careful consideration of the project’s specific requirements. Upon arrival, each component was installed, either integrated into the existing machinery or positioned adjacent to it, ensuring continuous operation of the production line throughout the process. Once the final components for the existing extruder system arrived, a temporary shutdown was arranged, allowing for their seamless installation and the initiation of testing.

Following the installation of all sensory, electrical, and mechanical components, trials began on Elviplas S.A.''s polyethylene production line in Komotini, Greece. These trials enabled thorough testing of each operational parameter to ensure accurate calibration and optimal performance. This step was crucial for validating that all parameters were fine-tuned to achieve maximum energy efficiency while maintaining product quality within the company’s specified standards.

The project will contribute to the minimisation of production faults and scrap due to machine failures and improper definition and control of production parameters, therefore increasing the output (efficiency), reducing energy consumption and minimising raw material use. The project will therefore lead to an increased turnover and net operating profit for Elviplas SA.