Automation of a Large-Scale Plant at Production Site in Eilenburg/Saxony

The company Polyplast Müller GmbH is a dynamically growing enterprise in the field of production of masterbatches and compounds for the whole polymer processing industry. This growth can also be seen in the newly built production site in Eilenburg.

The project partners in this project were Coperion Waeschle GmbH & Co. KG as project leader for the mechanical engineering as well as the delivery of the whole bulk handling system components, Reimelt Henschel MischSysteme GmbH as supplier of the heating-cooling-mixer, Brabender Technologie KG as supplier of the differential dosing balances, KraussMaffei Berstorff GmbH as supplier of the twin-screw extruder, Bruckmann & Kreyenborg Granuliertechnik GmbH supplied the underwater pelletizing system and Bruckmann Steuerungstechnik GmbH supplied the whole automation system. The plant construction was made by Polyplast Global Engineering GmbH (PGE) part of Polyplast Müller.

The basis for the engineering was the creation of a process and instrumentation diagram. Based on this, the electrical documentation under WS-CAD was built. After that, the switching station construction was made as well as ONEoperate, ONEview, ONEdatagate and ONEexchange (systems which are part of the scope of supply) were adapted to the line characteristics. All these project works are effected in the interdepartmental engineering center ONEtool. After completion of the mechanical superstructure and the electrical installation, start-up of the line was effected by our experienced engineers.

Feeding systems	Extruder	Batch process

The automation hardware is based on Siemens S7 components as well as two server PCs. Our system family is used. The production line is centrally controlled via ONEoperate. The production visualisation ONEview informs at a central location about the condition of the production line.

ONEdatagate

The heating-cooling mixer (picture) is automated by a batch control. The responsible, product depending master recipe for the mixer is stored in ONEexchange and is transferred to the mixer when the product is changed. The whole product process is consistently documented via the production analysis system ONEdatagate.