Sustainability is, or should be, a global target for everybody life and not only for the industries, but is for sure a clear target for the paper industry.
We all live in the same world, like a starship flying in the universe, with limited space, limited resources, but same environment.
We, in Pulsar, decided to contribute for a better future, improving our actions and especially supporting our customers to keep and reach their targets.
We support tissue producers to better handle the dynamic of consumer’s trends, which reduces the lifecycle of a product, with need of flexibility.
The vision we propose wants to be holistic, taking into account all the aspects related to the management of production and non-production operations, which have an impact on the effective sustainability of the whole.
In fact, we are convinced that the issue of sustainability must be addressed in its entirety, with a view to the process formed by subsequent phases and operations in sequence, where each element, each choice, each solution, can provide its contribution or, if not correct, decrease the effectiveness of the entire system.
Our Mission is propose to our customers solutions to better handle the products flow in their production and packaging lines, in a flexible, safe and sustainable way.
With our systems, we contribute to the process sustainability of our customer, proposing several different products and services conceived with focus on efficacy of the operation, efficiency of the process, safety of the operator, providing support to a real sustainability of the operations.
SMART LINES CONTROL SYSTEM
With our control systems for the management of the lines, we treat gently the products, reducing the scraps and the energy consumption: the speed of line’s running, can be adjusted according to specific needs.
Why run the line and products at high speeds if it is not necessary?
With adequate control of the speeds and conditions of transport of the products, it is possible to:
- reduce energy consumption,
- reduce consumption and wearing of materials
- reduce the need for maintenance and spare parts, increasing the efficiency of the system
- reduce collisions between products
- reduce friction on products, when accumulated, while preserving their integrity
REDS HARMONIZER PLATFORM
With our harmonizer system, we balance the flow according to the events along the line, avoiding unwanted continuous start and stop along the line.
Furthermore, with our smart controls systems, we reduce the energy waste, adapting the speed of the conveyors according to the real need at the time.
Correct coordination of the production process phases, characterized by continuous flow phases and intermittent operation phases, is essential to obtain adequate efficiency.
With the use of our harmonization software, we therefore obtain:
- substantial increases in efficiency, with a greater number of products made with the same operating time of the lines
- more regular production quality, thanks to the reduction of stops and restarts, which often generate transients with unacceptable quality
- reduction of production waste
ENGINEERING & LAY OUT
With our experience on the tissue converting industries, we can support our customer in the engineering and configuration of new production lines, or sites, helping them to define the most efficient lay-out configuration according to their targets
With our engineering skills, we propose lay out developed not only on floor space, but also organized on more vertical levels, reducing the precious space occupation of the floor (and of the soil) and creating free and safe passages for the operators to cross the workshops.
The occupation of spaces and surfaces is always a critical factor in the design of production plants.
An optimal lay out allows to obtain:
- better flow of goods and people, with the creation of more people-friendly, safe and efficient work environments
- less occupation of the spaces on the ground, with a potential reduction of the spaces occupied by the new plants and therefore a reduction in land consumption
- Consequent reduction of the construction costs of the plants and of the management and operating costs
- Higher overall level of automation, thanks to the possibility of managing constant, uninterrupted and well-conceived flows of products along the lines
AUTOMATIC SETTING
With our clever solutions we make easy the adjustment of the lines at products changeover, reducing waste of time, waste of products and safety risks for the operators.
One of the critical factors of all production processes, and in particular that of tissue, characterized by great variability of products and formats, is the management of product’s format and production changes, factors that always generate inefficiencies, delays and critical transition phases, difficult to manage.
The adoption of automatic systems for the format changeover phases, such as:
- automatic or facilitated adjustment of the side guides and passage of the products in the transport lines
- automatic adjustment of the operating parameters of the lines on the basis of different needs, through the management of pre-stored recipes
help to manage in the best way and in a constant and repetitive manner, without interpretation by the various operators, the critical phases of format change.
This is strongly improving the effectiveness of operations, reducing the necessary transition times, reducing the need for operators to move along the line for the various necessary settings, with improvement of the efficiency of the systems and of the working conditions of the people.
PRODUCTS CONFORMITY CHEKING SYSTEMS
With our Quatis and Vision quality inspection systems, we supply our customers with an unprecedented amount of accurate data about the quality of their products and about their line functionality, helping them to satisfy the high expectations of their customers and to improve the efficiency of their production lines
The continuous, constant and complete control of the quality and conformity and characteristics of the products passing through the production lines is an extraordinary tool for controlling the effectiveness and efficiency of the production lines itself.
Checking the essential characteristics of the products along the various stages of the process, means checking the effectiveness of the process immediately upstream, step-by-step, highlighting critical elements and allowing for gradual optimization.
The analysis of the products allows highlighting any cause / effect relationships between adjustments and parameters of the process machines, with the characteristics of the products obtained, thus allowing to highlight and anticipate any phenomena of performance drift, which can therefore be anticipated and corrected by automatic adjustment loops.
The modern technologies of data collection and analysis allow to carry out the analysis of the production process in a simple and rapid way as never before, even in real time, allowing it to be maintained at high and continuous levels of effectiveness and efficiency, without the need intervention by operators.
The opportunity to set completely automatic feedback signals and control loops, is also possible.
Results:
- increase in the effectiveness and efficiency of the plants
- reduction of machine stops for extemporaneous adjustments
- effective control of the lines, without the need for surveillance and intervention by operators, who can therefore devote themselves to more valuable tasks and activities
- Consequent reduction of energy consumption per production unit
- reduction of production waste
- reduction of complaints by distributors and consumers and possible returns of goods
LINES DIGITAL TWIN
With our Plant Layout Simulator, we build the “digital twin” of a customized production line, offering the possibility to tests the impact of different configurations, different processing machines, different products and different events normally happening in the production line.
In this way, we are able to predict the real behaviors and performances of an operating line, helping the correct engineering and manufacturing of the same, obtaining higher OEE.
The preliminary analysis of processes and flows, allows to correct any anomalies or criticalities already in the design phase, with consequent optimization of both the operating characteristics and composition of the lines and their layout, thus optimizing both the production flow, that the flow of people and goods, improving the use of space.
The adoption of digital twins of the line, also allows to anticipate the testing and calibration phases of the devices along the process flow, predetermining the operating conditions and parameters according to the various scenarios that arise and according to the various product formats to be managed
In this way, the phases of testing and calibration of the lines during commissioning is strongly reduced, with a consequent reduction in costs and time required.
SAFETY
With the design of our lines and components, we create a safe working environment, improving the safety of the operators and their health.
Safety of the operators and human health and wellness, is a crucial part of any sustainability program and safety of the production lines, has always been a crucial focus point for Pulsar development.
Pulsar has developed and proposes intrinsically safe systems for operators, as they are based on components conceived and designed specifically for these aspects, with the same operating efficiency.
The line of safety chains of the SB03 series are based on a patented design by Pulsar, which prevents the creation of pinching areas in the various paths, preventing operators from being injured or entangled in them, during normal line management operations.
The configuration of the lines and machines proposed by Pulsar are designed for safe operation and at the same time ergonomically designed for easy operation and management.
The use of the most modern technologies, from HW and SW safety circuits, to the use of collaborative robots, always guarantee maximum safety conditions.
Each line is qualified by an accurate risks assessment and analysis and calculation of the PL level reached, confirming that, for Pulsar, the safety is achieved by the design of the systems and not by the simple introduction of barriers and sensors at the end of the construction of the systems itself.
DIGITAL SERVICES
With our IOT platform, we created a virtual environment to be always close to our customers and their needs, even being physically far away, reducing the need to travel and the time for reactions.
The application of modern electronic communication technologies and remote data collection, allows Pulsar to provide support services to its clients, delivered through digital technologies, ranging from:
- Direct connectivity to lines and plants for remote assistance and monitoring, management of the operating data of machines and systems, supply of analytical reports on their systems, supply of IOT technologies, Data Analitycs, Data Mining
- Direct access by Customer Technicians to information, tutorials, indications and tips & tricks, which can be used to improve the performance of machines and lines
- Direct access to detailed technical information relating to the systems purchased and installed, from the technical operating documentation, to the HW and SW listings, to the test cards, to the spare parts lists
- Direct access to the spare parts database, with which to check availability of supply times, prices of the various components and book their purchase.
- Remote service provision, such as FAT and remote commissioning
- Remote training provision for its staff, with the possibility of direct interaction on the machines
- Implementation of assistance and problem solving actions remotely, with great precision and effectiveness and more
Each customer can have personalized access to the services offered, organized in a modular and scalable manner over time, based on actual needs.
Some of the fundamental services, such as those relating to the availability of information, are offered free of charge, by accessing a reserved area accessible from the company website, through personal availability, for other services, both subscription packages are available either in the «pay per use» subscription, and in the form of all-inclusive, timed packages.
RECYCLING AND WASTE MATERIAL RECOVERY
Pulsar has recently introduced on the market a proposal aimed at closing the cycle of production and use of the plastic material used for the construction of the chains of the conveyor systems of the products which, when replacing them, must normally be disposed of, with heavy direct costs and waste of material. .
Pulsar has identified and developed a method that allows the recovery of the material used for the production of other material suitable for the manufacture of chains that can be used in the new lines.
The development of a process that involves the recovery, washing, disassembly, sorting and grinding of the material and mixing with virgin material in calibrated proportions, has made it possible to obtain resins with properties suitable for use in transport systems, maintaining the basic characteristics of the original products.
With this initiative, therefore, Pulsar proposes an action of free collection of the materials replaced after maintenance activities, avoiding that the customer incurs disposal costs and processes them for the recovery of the plastic material, creating a real virtuous circuit with which to reduce drastically the ecological impact of the use of plastic material used in its creations.
With this process, for every kg of plastic thus recycled, an equivalent quota of at least 5 kg of equivalent carbon dioxide emissions are avoided, thus obtaining a significant impact on the reduction of emissions into the atmosphere and energy savings.
CONCLUSIONS
In Pulsar, we care and we will care about details, catching and anticipating the customers expressed or unexpressed needs and developing customized solutions, with clear focus on performance, sustainability and efficiency.
We build relations to least a long time and we integrate our knowledge with the one of our customers, protecting their ideas and helping them to reach their targets.
As a leading industry in the tissue converting area, we know we can make the difference and help our customers to reach their targets, even about the sustainability of their operations and development, helping to create a better world for our next generations.
We continuously put our efforts in improving our proposals and our attitudes, innovating and anticipating trends, needs, technologies applications.
Find out more how we could help also your company to reach your target of sustainability and efficiency, get in touch with us at customersupport@pulsarengineering.com