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Ogliari

Ogliari Company goal is to receive some basic data from a heat-sealing machine and an extruder machine, and to interconnect the latter one with the MES to increase efficiency.

Software 4.0 for the Interconnection of Machinery for a Packaging Company

The challenge

The Ogliari company produces professional packaging for food and pharmaceutical companies. The goal of Ogliari is to receive some basic data from a heat-sealing machine and a Hosokawa Alpine F3 extruder machine, and to interconnect the latter one with the MES to increase efficiency.

The aim is to automate data collection, to trace machine states, the number of pieces produced, to know the speed and production time, the working and set-point temperatures, the thicknesses and the quantity of the plastic films produced.

The second goal is to seize the opportunity offered by the Italian National Industry 4.0 Plan, which offers state incentives to promote the technological innovation of the country: it is, therefore, necessary to respect the requirements of the legislature in this regard.

The solution

To meet the needs of Ogliari, we used our software for Industry 4.0: iDaq, Digital Factory 4.0 and Lilium, achieving the objectives with a complete and scalable solution in a short time.

iDaq is used to communicate directly with the machines (heat sealer and extruder) through OPC protocol and through other dedicated protocols.

iDaq collects the main production data listed below.

Data acquired from Hosokawa Alpine F3 film extruder:

Machine status
Working and set-point temperatures
Production speed
Thicknesses and quantities of the plastic films produced (extrusion quantities)

Data acquired from Mobert G200 heat sealer:

Machine status
Number of bags produced
Production time

Digital Factory 4.0 provides a global view of the plant and forwards the parameters of the batch to be performed on the Hosokawa Alpine F3 machine on the basis of what the operator has chosen from the MES.

Lilium deals with the transfer of data to the company database, from which the MES extrapolates the information for viewing and archiving, and the transfer of data from the database to Digital Factory 4.0 and iDaq.

Diagram of the interconnection of Hosokawa Alpine F3 film extruder and Mobert G200 heat sealer

Diagram of the interconnection of Hosokawa Alpine F3 film extruder and Mobert G200 heat sealer

Benefits and Results

All the pre-set objectives have been achieved, allowing Ogliari to obtain significant benefits:

Time-saving: the items to be produced by order initiated by the MES are sent directly to the specific machine involved.
Cost determination: with all the automatically collected production data it is possible to have an accurate cost report.
Reduction of human errors: data acquisition is automatic, reducing errors due to manual operations.
Traceability: all the data of the production cycle are tracked and there is a production history committed per batch.
Company interconnection and tax benefits: the legislature requirement for company interconnection between machinery and management has been respected in order to have access to tax benefits offered by the Italian National Industry 4.0 Plan

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“I am very satisfied with the collaboration we had with T4SM in the realization of this project. In addition to demonstrating considerable technical and design expertise, they were able to propose innovative and very useful solutions, which now allow us to have a constantly updated and monitored situation in our production process.”

Osvaldo Ogliari
Owner
Ogliari