Case Study: Plug-and-Play Pneumatic Upgrade Supplied by Camozzi Automation to Leading Kitchen Manufacturer

A leading UK kitchen factory was struggling with a number of outdated pneumatic backplates that were being used to control production lines for kitchen cupboard assemblies. Fault-finding and maintenance were challenging due to colour-coded pipework and monitoring system being absent. Health and safety were also compromised as the original system incorporated safety features and omitted a number of important safety features.

One of Camozzi’s premium distributors, Engineers Mate® – part of the IADA group – approached Camozzi for assistance with the replacement of three initial backplates: one air preparation set and two valve control backplates.

Representatives from Camozzi Automation, including the technical application team and the distributor, visited the site to meet the team, understand operational and safety issues and discuss the customer's requirements.

Three new backplate replacements were requested by the customer, new valves, colour-coded pipework to assist in fault-finding and as many new safety features as was considered prudent.

Camozzi Automation's application team recommended the design of a full operating circuit and full schematic drawings with valves clearly marked to assist future maintenance.

Solution

The Camozzi technical applications team went about redesigning the backplates from drawings provided by the original machine maker. The new designs featured safety and performance provisions discussed. The team were tasked with working in close proximity and were provided with accurate dimensions and mounting hole positions to allow for easy fitment.

Enhancements included:

• Colour-coded tubing tailored to the customer's specifications
• Dual Safemax MX safety dump valves with ISO 13849-1 (Performance Level e) monitoring to operate rod lock devices on selected cylinders

Custom, dimensionally matched cylinders from Camozzi were also supplied as a one-off order. They were manufactured in the UK for the application, offering an upgraded value solution above the standard components.

Production progressed with the design approved.

Result

The new Camozzi backplates were commissioned, tested and installed by the customer successfully. With this success under our belt now, negotiations are afoot to replace the remaining nine backplates on other machines and production lines, as well as other pneumatic equipment.

The new panels and cylinders cut air leaks dramatically, generating improved energy efficiency and resultant cost savings.

The system came supplied as an install-in plug and included specially profiled cylinders to match the customer's existing non-ISO models—offering a disruption-free, seamless upgrade.

“The whole engineering team were very taken with the quality of manufacture and the ease of fit. The change away from the bashed, cluttered old panels to tidy, rational new ones has been an improvement.”
Rob Beech, Director, Engineers Mate®

Boilerplate

Camozzi Automation is a member of the Camozzi Group and specializes in designing and providing industry with products and solutions.

Camozzi Automation's product offerings include motion and fluid control components, systems and technologies for industrial automation (packaging, food & beverage, plastics, robotics, printing & paper and textile machinery) and for transport and life science industries.

The company is increasingly involved in the development of IIOT (industrial internet of things) solutions and products. Camozzi encourages digitalisation of production processes and the creation of smart components for real cyber-physical systems. This allows mechanical, electronic and digital components to be combined, optimising process performance and data management on a continuous basis.

For further information, contact:

Camozzi Automation Ltd
Tel: 024 7637 4114
E-mail: sales@camozzi.co.uk
Web: www.camozzi.co.uk