Keeping an eye on the plant

Where plant downtimes entail enormous costs, condition monitoring offers manufacturers and operators valuable insights. Reifenhäuser Reicofil has taken an important step in this direction with the condition monitoring of the SIMATIC S7-1200 basic controller.
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Right from the start, SIPLUS CMS1200 has proven itself to be the best solution for meeting our expectations – and we always want to use the best.
Georg Breuer, Purchasing Manager at Reifenhäuser

Whether cosmetic tissues, tea bags, upholstered furniture, or vacuum cleaner bags, almost every area of everyday life involves nonwovens of some kind. Because they are used in such large quantities, the worldwide market for nonwovens is challenged to produce at ever higher throughput rates while running the machines for longer. As a manufacturer of such plants, Reifenhäuser Reicofil, decided to find the right solution for condition monitoring (CM).

The company’s control topology has traditionally been based on SIMATIC S7 controllers, which flexibly and efficiently perform automation tasks in the environment of nonwoven plants. This made the decision easy for the optimal CM system: Reicofil opted for the scalable and modular SIPLUS CMS1200 condition monitoring solution. The SIMATIC S7-1200 CMS SM1281 module constantly monitors the condition of the mechanical components, creating the basis for predictive maintenance and an early detection of faults.  

We opted for this CM system because it can be so easily integrated into our existing control and automation system.
Thomas Fett, head of electrical design at Reifenhäuser Reicofil

Easy-to-integrate solution

The SIMATIC S7-1200 basic controller can be expanded in a straightforward manner to include up to seven CMS SM1281 modules. Each module can then be connected to a maximum of four IEPE acceleration sensors. Evaluation, diagnosis, and visualization are available via web browser and do not require any additional software. The analysis results are simply sent back to the basic controller and its SIMATIC CPU 1214C. From here, data can be transferred directly to MindSphere, the cloud-based, open IoT operating system    

Up to 160 measuring points are available in nonwoven plants of the highest configuration using the SIPLUS CMS1200 condition monitoring system. These plants include bearings, gearboxes, compressors, and motors that are linked via Industrial Ethernet communication using 45 SIPLUS CMS1200 devices with up to 13 SIMATIC S7-1200 CPUs. 

A win-win situation

Thanks to SIPLUS CMS1200, Reicofil is able to always keep track of the machine and accurately record its condition by monitoring signals. This deep insight helps the plant manufacturer perfect their own designs and supports commissioning of new machines.


Reicofil customers also benefit from the integrated condition monitoring that results in continuous condition diagnosis: Higher availability and increased production are extremely advantageous, as unplanned downtime is avoided. In addition, the exact location where faults might occur can be identified early-on. This information helps to make qualified decisions whether a replacement of a bearing, gearbox, or motor can wait until the next planned shutdown. since many spare parts are delivered just-in-time, plant operators can use this information for a precise order management.

Future. Flow. Fascination.

Reifenhäuser Reicofil

With some 1,600 employees worldwide, the Reifenhäuser Group is one of the trendsetters in building systems and components for plastics extrusion. Founded in 1911, the family-owned and operated company supplies high-tech plants for blown films, cast films, smoothing films and nonwovens in every industry. The company also operates what it describes as the world’s largest research and development center for plastics extrusion technology at its Troisdorf site near Cologne, Germany. 

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