Industry 4.0 is a word that is batted around the plastics processing industry a lot these days, but what does it really mean and how is it most usefully applied?
Frigel
To temperature control industry leader Frigel, the notion of Industry 4.0 could mean everything to some customers and nothing to others, and when it comes to chillers, is Industry 4.0 something they are looking for when considering that part of their production line? Instead of slapping Industry 4.0 labels on its new developments, Frigel prefers to use the words ‘advanced digital control’, when developing its technology to improve customers’ sustainability, quality, productivity and profitability.
At NPE 2018 in Orlando, Frigel showcased the extension to its digital control technology for the Microgel RCP Chiller.
The Microgel RCP Chiller does away with central chiller systems in PET preform, large-part blow moulding and high-speed multi-cavity injection moulding applications. By taking the capabilities of the unit to the next level, the addition of advanced digital controls gives users the ability to capture process-cooling energy consumption data and more easily adjust the unit for specific moulding conditions for optimal efficiencies and cost savings.
“The goal is to help customers have a true feeling for the kilowatt per kilogram of resin for processing because nobody takes into account the chillers,” explained Al Fosco, Marketing Manager, Frigel North America.
Industry four-point-oh?
Fosco steers clear of the term Industry 4.0 because he is aware there is an ambiguity around the phrase to those who haven’t been instrumental in its rise through European plastics processing in particular. Without putting a label on it, the concept of connectivity and control makes sense in cooling as the next step for capturing data in a way that is secure and easy to access, but Frigel’s technological evolution is one borne of its own innovations and developments, and not the company jumping on the Industry 4.0 bandwagon.
“Duccio (Frigel CEO Duccio Dorin) doesn’t want to say ‘let’s create Frigel 4.0’,” said Fosco.
Frigel
The new control updates allow customers to access data anywhere in the world from their chilling systems connected to their injection moulding units to help them close the loop at thermal load and energy, flow and temperature. This is something Fosco believes will appeal the most to bigger customers, but it will be interesting to see if smaller plastics processors are looking to access more data about their chilling technology.
Plastics on repeat
The Microgel RCP Chiller is engineered with a high-efficiency, high flow/pressure process pump, enabling it to provide turbulent flow and low temperature rise across large and multi-cavity moulds. The unit also features motorised servo-modulating valves, eliminating sharp temperature peaks and valleys found with traditional on/off solenoid valves. The digital control extension technology allows the customer to use onboard troubleshooting technology combined with monitoring technology to manage data from units all over the world in one place, allowing service departments to work remotely.
In addition, the technology allows customers to ensure they are creating the exact same plastic parts, whether the mould is in Italy, the US, or China, or in all three locations making the same part. Once the chiller settings are optimised for that tool, the data is stored so in a month’s time, if the mould is put back in the machine, the operating parameters are set and ready to go – and if something goes wrong then it is likely to be something outside of the Microgel.
“You set the flow for a specific tool and if it reads above or below that pre-set band an alarm will be sent,” explained Fosco. “It allows those with a global company that’s making the same car bumper in the UK that they have in production in the US on the same machine to ensure that those two chillers across the Atlantic are operating exactly the same. So, once they certify that tool, wherever it may go they can globally produce that part and make sure they have proper flow. Guaranteed repeatability, no defects, no warping. That mould should work the same today as it does six months from now.”
Savings for success
The package Frigel offers customers is reliability, quality and sustainability, and the new control system for the Microgel gives out energy readings to allow customers to keep on top of their consumption, while helping to reduce their carbon footprints by supporting water savings and energy savings.
“Sustainability is Frigel’s middle name,” Fosco said. “Variable speed drives ensure that the pumps operate at speeds commensurate with the mould requirements, so you’re only using the energy required for that tool, and customers get real-time data including energy readings.”
The lifespan of a Microgel, which is built to suit the needs of individual customers, is around 20 years, and Frigel is confident in its understanding of customers’ requirements and the robustness of the technology to provide an ROI with all its systems, including water savings, chemical savings and energy efficiency, allowing prospective customers to compare Frigel’s data with a competitor.
“We send Microgels out all the time on trial and we’ve never had one come back that I know of,” Fosco stated. “We give you 30-60 days and we help set it up and inevitably customer cycle times are reduced and they’re making better parts. It’s been very successful.”
This, along with a custom-made solution for each plastics processor, is all part of Frigel’s ‘Diamond Service’, which promises to continue delivering the best in process cooling technology to ensure customers have the competitive edge.
“I started in 2009 with Frigel and I was excited about the features and the equipment then - but they don't stop improving,” said Fosco. “What we’re doing is enhancing the products to make them even more sustainable and energy efficient. That’s the Diamond Service advantage.”
