Even machines get older. The good news from Optima: something can be done about this that goes far beyond cosmetics and plastic surgery. This is particularly important when a machine is responsible for the ability to deliver, for example. This is precisely the situation that Optima Consumer's service encountered at Milcafea GmbH, Rathenow, a manufacturer of powdered drinks.
The system, in this application example a OPTIMA FRK, has been reliably dosing coffee and mixed drinks, such as cappuccino, for over 15 years. Although the rotary machine was still running excellently, Milcafea did not see a „golden autumn“ approaching, but rather massive problems for the machine: Suppliers of electrical components are stopping production of various components shortly. Reduced stocks in the Optima warehouse would no longer be able to guarantee a reliable supply in the medium term. Discussions therefore centred on Machine update to the latest electrical and software version from Optima. This would ensure the availability of spare parts for many years to come.
Once again, this project demonstrated the importance of close coordination between the customer and service provider. „The ideas on how we could improve the system as part of an upgrade were just bubbling away as we inspected the machine together,“ explains Andreas Noller, who was in charge of the project as an electrical designer at Optima. They then negotiated which additional measures could be implemented and in what time frame. The overall package was put together under the motto „What costs little time and brings a lot“.
Operation under power
An agreement was reached and the project was implemented. The first measure concerned the control cabinet. The system dates back to the days when such cabinets were large and powerful and took up a lot of space next to the system. The current idea: the now much slimmer control cabinet could be relocated to a technical floor below the production level. Overall, the electrical system has been modernised and the machine appears almost „empty“. With the extra space, the bottling company now benefits from the following on the production level significantly improved hygiene properties. Coffee powder, which always scatters easily into the machine, can now no longer spread under the control cabinet. The machine environment is much easier to clean than before.
The electrical update was also extended to a product feed above the OPTIMA FRK. This is from the same year of manufacture, but not from Optima. As part of the upgrade, the control of this machine was „outsourced“ to the HMI of the Optima system. Operation of the entire system is now significantly simplified. There is now only one HMI to operate and staff no longer have to internalise two differently structured control systems. The overall menu follows a standardised logic. Of course, the new electrical system is also protected by Optima Service.
At the same time, the new control system More even product flow achieved. The filling accuracy, with which the customer was already very satisfied, has improved significantly once again.
Another significant advantage after the conversion is the Service access via Remote Controll. In the event of system malfunctions, the operator can grant Optima Service direct access to the machine control system. These measures increase overall system efficiency: in the short term in the event of machine malfunctions and in the medium to long term for all necessary electrical components that need to be replaced.
A defect is always annoying, but the consequences are now manageable again at Milcafea. The ability to deliver is assured. The electrical system and software are on a par with a machine delivered by Optima in 2018. So like newborn.
Andreas Noller, electrical design engineer at Optima, emphasises: „Soon, some older electrical components will no longer be produced by the manufacturers. Milcafea took action in good time and carried out an upgrade.“
3, 2, 1, go! The clock is ticking ...
The most important criterion for the client was the time factor. After all, the customers - predominantly discounters - have to be supplied just in time.
The conversion of smaller systems or particularly extensive service orders are carried out by Optima entirely in Schwäbisch Hall. In this case, the assembly and dismantling of the OPTIMA FRK alone would have taken too much time. The idea of relocating the control cabinet to the technical floor opened up the possibility of using the Milcafea extensive preparatory work during ongoing production to be carried out. Nevertheless, everything that could be prepared in Schwäbisch Hall was prepared there. This included the initial set-up of the electrical system with components such as servomotors and sensors together with the newly installed control cabinet and the new software. Only the mechanics, which were in good condition for this project, were left out. This meant that part of the system was ready for simulations. „We were able to test more than 50 per cent of the system in this way,“ says Stefan Burk from Optima, who supports Milcafea in the service department.
Mistakes can always happen, whether in the design, in the software or, for example, during wiring. However, it becomes complicated and time-consuming if these errors are only noticed during commissioning on site. Even the tendency control can be via simulation check. If the checkweigher detects a (fictitious) overfill, the dosing unit's servomotor must reduce its speed. At the same time, small changes such as stainless steel housings on the filler, which are now standard, are being prepared.
Preparations started on site at the customer's premises, partly in parallel. Openings were made in the technical floor and cable ducts were laid. With the decommissioning of the „old“ OPTIMA FRK, things finally got serious and the clock was ticking relentlessly. The old electrical system was cleared out, the machine dismantled, the prepared cable harnesses installed and connected. Ten days were allowed for the complete set-up, during which everything from the HMI to the line connections after the checkweigher was prepared for recommissioning. After a further three days for commissioning, the system started up as planned.
Fast restart of production
Optima's ramp-up support also included training on the system, as the operation of the machine had to be learnt in the same way as a new machine. In order to enable the customer to start production as quickly as possible, an electrician and a software specialist were on hand at the machine during the first few days. They carried out fine adjustments and explained the new mode of operation to the employees - and they coped very well with the more intuitive operation and new visualisation.
The total time saving achieved through the relocation of the control cabinet, the simulations and other measures is estimated at around three weeks. For Milcafea, however, only one thing counts: the customers could be supplied completely and smoothly from pre-production.
[infotext icon]Retrofits and ramp-up support are part of the comprehensive Optima Total Care service concept. With the Optima Total Care portfolio, the company is taking service to a new level. Services in every phase of the system life cycle support production efficiency. The services range from project planning to (digitalised) production. Optima's ramp-up support focusses in particular on the time factor and ensures that the rejuvenated machine is back in production as quickly as possible[/infotext].
