Setting new standards with clever concepts

Zippe is implementing customer-specific, automated, and highly efficient batch and cullet plants worldwide – as demonstrated by the examples of Vetri Speciali in Italy and Industria Vidriera de Coahuila in Mexico.

As a longtime partner, Zippe Industriean­lagen GmbH in Wertheim, Germany, has comprehensive expertise when it comes to Siemens control systems. Regardless of whether the customer chooses a Simatic PCS 7 process control system or a Scada solution based on Simatic WinCC combined with Totally Integrated Automation, Zippe generates solutions precisely tailored to the customer’s needs based on established standards. This is confirmed by several recent projects.

Both projects demonstrate that networking is progressing rapidly and that Industrie 4.0 is an integral part of today’s ­automation solutions from Zippe.
Joachim Ullrich, Head of the Control System ­Construction Department at Zippe

For plants of any size

For many years, Siemens controllers, drive technology, HMI systems, and sometimes even measurement technology have composed a sort of in-house standard for Zippe plants of all sizes. Recently this has come to include the latest generation of Simatic S7-1500 Advanced Controllers as the foundation for more ­complex batch house control systems.

Vetri Speciali: Special glass made in Italy

The same applies to a successfully completed project for Vetri Speciali. Vetri Speciali is both the name and the product line of this globally active manufacturer of hollow glass containers for special applications based in Trento, Italy. Zippe implemented a batch plant for the Italian company with raw material feeding and a premix plant, including a cullet-return system with a scraping conveyor and glass level controller. The glass specialists from Wertheim, Germany, were also responsible for the control systems, including the commissioning of the electrical systems and start-up of the plant.

“The operator chose a Siemens solution because it ­seamlessly connects the automation level and – with WinCC – the Scada level, supports the latest operating concepts, and provides the high level of system performance desired,” says Joachim Ullrich, head of the Control System Manufacturing Unit at Zippe.

Simatic S7-1500 Advanced Controllers from Siemens have become established as the foundation of more complex automation solutions for Zippe batch plants.

Integration à la Industrie 4.0

Redundant servers guarantee high availability and allow batch-plant, silo-feeding, and cullet-return system operation to be centrally coordinated from the furnace control room. In addition to the PC-based control stations, the cullet plant can be monitored locally by means of Simatic touch panels.

Along with Siwarex weighing systems from Siemens, Zippe also installed its own weighing indicators that were specifically developed for the glass industry. Both systems transmit the weights of raw materials and cullets as well as data from mixer and check scales to the central control system. Thanks to the precise ­electrical activation of the dosing equipment, dosing is accurate to within one gram.

Filling-level sensors from Siemens’ Sitrans family continuously determine the filling level of the silos and transmit the analog measurement signals to the Scada system via the SPS. Frequency converters and bar code readers for silo selection can also be easily integrated. Simatic MP277 IWLAN V2 Mobile Panels also proved their worth as flexible operating units in the field from the very start. In many applications, tried-and-tested Scalance W788-1 Industrial Ethernet access points ensure a stable Industrial Wireless LAN and connection to the control system.

Industria Vidriera de Coahuila: Batch plant in Mexico

Based on the same successful concept, Zippe built, fully automated, and networked a new batch plant in the northern Mexican city of Nava, about 30 kilometers from the Texas border. The plant is operated by ­Industria Vidriera de Coahuila (IVC). The glass factory produces bottles exclusively for the company’s own large brewery that’s located next door. The new turnkey batch plant from Zippe reliably feeds a furnace that produces 560 tons a day. The equipment suppliers also delivered cullet-return systems for two more new melting furnaces.

Separate Simatic S7 controllers coordinate operation of the batch-plant, silo-feeding, and cullet-return systems. Here again, two redundant WinCC servers and several decentralized Simatic Comfort Panels ensure reliable operation and maximum availability. At IVC, a Simatic Mobile Panel supports mobile ­operation and monitoring in the area of the weighing systems. Scalance access points from Siemens ensure optimal wireless network coverage. Totally networked weighing indicators can be accessed from stationary operating stations and mobile panels: for example, to calibrate scales on-site or to diagnose them ­remotely.

Picture credits: Siemens AG

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