How can data acquisition help reduce waste in continuous printing processes?

High-resolution, time-synchronous data acquisition enables detailed analysis of critical process phases such as reel changes. With ibaPDA, signals from sensors, control systems, and control loops are continuously captured and correlated. This allows precise identification of root causes for web tension deviations. Based on these insights, targeted optimizations can significantly reduce waste.

How can complex interactions between control loops in printing processes be analyzed?

Modern printing systems involve multiple interacting control loops. By synchronously capturing analog and digital signals with ibaPDA, these interactions become transparent. Data from independent systems, such as register control, can be combined with control system data via modules like ibaBM-DPM-S. This enables a holistic analysis of process dynamics.

How can web tension issues during reel changes be reliably identified?

Web tension deviations are often caused by incorrect timing or unstable mechanical components. With ibaPDA, acceleration, pressing behavior, and cutting processes can be precisely analyzed over time. Correlating these signals reveals critical deviations during reel changes. This enables targeted optimization measures, for example in the hydraulic system.

What role does integrating multiple data sources play in process optimization?

Combining sensor signals, control data, and analog measurements is essential for in-depth analysis. With ibaPADU, analog signals are digitized directly, while fieldbus data is integrated via modules such as ibaBM-DPM-S. These datasets are synchronized and processed in ibaPDA. This creates a complete process view that enables targeted optimization.

How can process optimizations be validated using data?

After implementing changes, their impact can be directly verified using recorded data. With ibaAnalyzer, before-and-after comparisons can be performed to quantify improvements. Long-term data also enables assessment of process stability. This ensures that optimizations are sustainable and deliver reproducible results.

Data Acquisition for Troubleshooting and Process Improvement

Packaging Manufacturer Reduces Waste in Gravure Printing

Gravure printing is used for print jobs with a high edition of usually more than 300,000 copies. With the increasing competition on the market, the packaging manufacturers are constantly striving to enhance the efficiency of their plants, especially to reduce the set-up times and the waste. For this purpose, it is important to know and analyze exactly the processes running on the machine.

Business Benefits The Technology Used Functions More Success Stories

A critical point in the printing process are the changes of the rolls that are done as flying roll changes at full production speed – appr. 50 times a day. On the reel at the end of the printing line, an empty winding tube is accelerated on a second rewinder, until the circumferential speed of the tube matches the speed of the chilling line. The empty tube is stuck to the chilling paper web. Simultaneously, the printed roll is cut and ejected.

When changing the rolls, the web tension is of special importance. The timing of acceleration of the shell, pressing and cutting must fit exactly. Fluctuations in web tension inevitably lead to a defective print image and hence waste that has been up to now always at 40 meters.

Real-time monitoring

of the machine status

Immediate detection

of deviations

Overall data acquisition

and analysis of different control circuits

Reduction

of tolerance variations

The Technology

Using the iba system, procedures and interactions, especially in the field of roll changes could be made visible and traceable. Optimizations in the hydraulics of the reel winding resulted in a considerable stabilization of the tension of the paper web. As a result, the waste is only 5 meters now.

A close-up of discarded paper strips with colorful printing calibration bars.

With a computer in the central server room, with ibaPDA, measurement values are acquired and recorded. ibaPADU devices convert ±10-Volt signals that come directly from the sensors and from the register controls on the machine into digital measurement values. The Profibus-Sniffer ibaBM-DPM-S supplies data coming from the control of the machine. The register control of the gravure printing press is an autonomous control circuit. The analog signals of this control circuit are acquired time-synchronously with the data of the Profibus in ibaPDA. The analysis of the data showed that the adaptations in the hydraulics of the pressure roller ensured a better print image when changing the rolls.
The waste could finally be reduced by 90%.

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Used Functions

The following functions of the iba system are used in this success story.

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Frequently Asked Questions (FAQ)

How can data acquisition help reduce waste in continuous printing processes?: High-resolution, time-synchronous data acquisition enables detailed analysis of critical process phases such as reel changes. With ibaPDA, signals from sensors, control systems, and control loops are continuously captured and correlated. This allows precise identification of root causes for web tension deviations. Based on these insights, targeted optimizations can significantly reduce waste.
How can complex interactions between control loops in printing processes be analyzed?: Modern printing systems involve multiple interacting control loops. By synchronously capturing analog and digital signals with ibaPDA, these interactions become transparent. Data from independent systems, such as register control, can be combined with control system data via modules like ibaBM-DPM-S. This enables a holistic analysis of process dynamics.
How can web tension issues during reel changes be reliably identified?: Web tension deviations are often caused by incorrect timing or unstable mechanical components. With ibaPDA, acceleration, pressing behavior, and cutting processes can be precisely analyzed over time. Correlating these signals reveals critical deviations during reel changes. This enables targeted optimization measures, for example in the hydraulic system.
What role does integrating multiple data sources play in process optimization?: Combining sensor signals, control data, and analog measurements is essential for in-depth analysis. With ibaPADU, analog signals are digitized directly, while fieldbus data is integrated via modules such as ibaBM-DPM-S. These datasets are synchronized and processed in ibaPDA. This creates a complete process view that enables targeted optimization.
How can process optimizations be validated using data?: After implementing changes, their impact can be directly verified using recorded data. With ibaAnalyzer, before-and-after comparisons can be performed to quantify improvements. Long-term data also enables assessment of process stability. This ensures that optimizations are sustainable and deliver reproducible results.