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NPE2018 Show Daily - Monday

NPE is truly ‘Breaking the Mold’ as a multifaceted experience, with activities, discoveries and opportunities to satisfy the needs of anyone who works in the plastics industry or has a need to know about plastics

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MONDAY NPE 2018 : THE PLASTICS SHOW SHOW DAILY We strive to advance the performance of our customers' end products by delivering a broad portfolio of innovative polymers that are found in nearly every sector of the economy. Visit us in room W206 or go to lyb.com/NPE. Wire and Cable Coatings Textiles Water Pipes Food Packaging Automotive Exteriors/Interiors lyondellbasell.com/NPE Making Better Products Possible Dri-Air Readies Its Dryers for Industry 4.0 Today, and Industry 4.0 in the Future Dri-Air's newest dryer line offers heightened connecঞvity today with the capability to fully harness the power of Industry 4.0 as it develops. By Tony Deligio Plascs Technology At NPE2018, the company is introducing the Dri-Air Dryer 4.0 (Booth W971) to give its customers a resin-drying technology that's up to speed with what 4.0 means today and one that can adapt to where the industry-wide movement is headed in the future. Charlie Sears, Dri-Air's president, says the Dri-Air Dryer 4.0 uঞlizes the OPC-UA protocol, developed by Europe- an plasঞcs machinery associaঞon, Euromap, and intended to be the common language that all these newly conversant ma- chines will speak in the future. But Sears, who has been with Dri-Air since 1985, and in the industry longer, brings a lile perspecঞve to the 4.0 hype. "We have used the OPC-UA protocol," Sears says, "but there is more to it." Sears notes that Euro- map is in the process of seমng up the complete protocol, including, ulঞmately, where specific pro- cess informaঞon is located and what informaঞon is included, but when that actually occurs is as yet unknown. "Unfortunately we do not see this hap- pening soon," Sears says, "so the progress of 4.0 will be slowed down." That said, whenever these protocols are fully developed and implemented, Dri-Air is in, Sears says. "Industry 4.0, or whatever you want to call it, will be fully developed during the next few years," Sears says. "Currently it is a concept that will use all informaঞon available to make decisions of operaঞon. Dri-Air supports this effort and will be developing more ways to be- come efficient and adapt to the surroundings." For Dri-Air's Dryer 4.0, a primary emphasis is connecঞvity, and for customers with mulঞple Dri-Air Dryer 4.0s, a central dryer control is available, with access to each dryer's operat- ing parameters and other important data. When a dryer needs servicing, an icon flashes showing what needs to be done, with direcঞons for service and the parts required. The dryer's motor control monitors motor performance, reporঞng this data to the main control. As a new Dri-Air 4.0 dryer is in- stalled, it is automaঞcally added to the group display, Built with a modular construcঞon, the Dri-Air 4.0 controls idenঞfy which module needs replacing in a maintenance sce- nario, with instrucঞons on how to install it, and whether it is in stock. The dryer's wireless technology allows processors to compare cycle ঞmes among dryers, molding machines and robots to determine the opঞmum cycle for your equipment. When a dryer is moved, Dryer 4.0 automaঞcally senses the shi[ and changes the rotaঞon as needed, eliminaঞng the need for maintenance to rewire the rotaঞon on blowers. Solid state relays monitor the heaters, reducing the need for alarms. By sensing and controlling air flow, temperature and hopper content, to create low return temperatures, the dryers can eliminate heat exchangers in processes that exceed 250 F. Laser sensors and load cells monitor material levels in dryer hoppers, calculaঞng resin throughput for opঞmum operaঞon. Dri-Air Dryer 4.0 adjusts fill ঞme automaঞcally to prevent material from spending too much ঞme above the feed throat, and the system adapts air flow and process temperature by using a "sleep mode" that idles in the regeneraঞon cycle, re- ducing operaঞng energy by 80%. Another fundamental concept is bringing a key element of Industry 4.0—data-driven decision making—to smaller shops. Explains Preston, "We decided that the 'smart factory' should not be only for large mulঞnaঞonal organizaঞons. We built Smart Aend to bring the benefits of real-ঞme manufacturing data to entry-level companies and owner-operated firms that need to move themselves forward in compeঞঞveness." Data-driven decision making, adds Rizzo, "is a quantum shi[ in how people run their business. In many shops today, people come in Monday morning—or any morning—and get together to discuss the weekend's or last night's problems, and then people fan out to try to gather informaঞon on what went wrong and why. With Smart Aend, there's no need for morn- ing meeঞngs. Problems were idenঞfied when they happened overnight; the appropriate people were noঞfied; and they had data in their hands that could help them find a soluঞon right away." He cites the example of Smart Aend's Pareto charts that make it quickly apparent to managers where (or when) their biggest—and most expensive—sources of downঞme and quali- ty problems are occurring. "It takes away redundant, burden- some thought processes from managers and highlights their top three or five issues that need aenঞon." "For us, the importance of Smart Aend has been monu- mental," says Rizzo. "We're a lean Just-in-Time operaঞon. We don't hold safety stock for our customers. We can't make mistakes. One of our biggest problems was the human interacঞon—manually entered data, which could be missing or inaccurate. Smart Aend ends that. Smart Aend does not have opinions; it has data." Home Grown, conঞnued from page 22 24

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