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Extruder Retrofit for an Obsolete Control System

A packaging customer had an obsolete control system on their extruder, winder, and thermoforming lines. Was there an affordable solution to retrofit it?

Challenge

The customer had an obsolete control system on their extruder, winder, and thermoforming lines.

The customer asked ICS to develop a low cost retrofit package.

Services

Results

Working with the customer to solve this problem, ICS was able to:

  • Create both a field retrofit and new panel solution.
  • Upgrade the old DC drive and motor to AC technology.
  • Remove old mercury relays from cabinet and replaced with Solid State Controls.
  • Replace antiquated HMI controls with ICS easy to use extrusion controller.
  • Upgrade the old tension control system on winders to new open loop technology.
  • Upgrade the obsolete servo controls with Rockwell Kinetix servos.

Relevant Industries

Packaging →

Benefits of rebuilding:

  • More reliable extruder.
  • Reduce downtime by eliminating old DC motor.
  • Improved operating efficiencies.
  • Up to date extrusion control system.
  • Easy to train new operators.
  • Improved tension control on winder.
  • Better quality rolls.
  • Higher throughput.
  • Less scrap.
  • Increased profitability.
  • Local and Nationwide stock on parts.

Integrity Control Services
Automation implementation, integration, and maintenance for any industry.

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