Smurfit gains operational efficiency boost thanks to Siemens technology

Phil Black - PII Editor 07/12/2009

108 2 minutes read

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Smurfit Kappa Group is one of the world’s largest integrated manufacturers of paper-based packaging products, with operations across Europe and Latin America.

Smurfit Kappa Totana, Spain is involved in the manufacture of pre printed Linerboard destined for its corrugated factories in Spain and Italy. The Cobden Chadwick 7 colour press used for the purpose had an unreliable drive positioning system that was starting to cause excessive downtime issues, creating maintenance difficulties for the site’s management. The existing closed loop servo system was also obsolete and unreliable, thereby affecting the overall operational efficiency at the plant both in terms of production potential and ongoing maintenance concerns.

In the existing system, each four axis set would position large print and ink cylinders to micron precision to print images on paper web running at up to 350m per minute. The positioning adjustments were achieved with hand held pushbutton stations fitted with flying leads.

To achieve more accurate printing results, provide more flexibility and a system assured of serviceability into the future, a team from systems integrator, MC Drives and Controls, installed some of the latest technology from Siemens Industry Automation & Drive Technologies (IA&DT) including Siemens Sinamics Servo Drives, wireless operator handsets and a S7 PLC.

The team from MC Drives removed the existing 28 axis system, designed and built a new backplate featuring drives from Siemens IA&DT, created a new operator desk and installed wireless handsets.

The new system installed is unique because it uses wireless handsets which incorporate a mini HMI and touchscreen. Operators can stand wherever they wish to make adjustments to all 28 deck axis and a further 13 register axis, offering a significant increase in its flexibility. The new system retains the existing servo motors, but incorporates newly-fitted Siemens servo drives to boost its performance. While a new S7 PLC calculates the deck positions and sends the positional data to the drives for them to achieve and maintain the desired positions. The system utilises a method of referencing which ensures the final print positions are extremely accurate.

Barry Smith, Technical Director at Smurfit Kappa, explains how significant the benefits of the new system have been: “We have been impressed with the design of the new system and the flexibility and reliability it offers to the press but once again, the solid support from MC Drives, which was a key factor in choosing them for the project, has given us an almost fault free start up to the system.”

For any further information, please contact 0845 7705070 / www.siemens.co.uk/automation.

For any further information on Mc Drives, please visit www.mcdrives.co.uk.