PLC retrofit at a toner factory – Xeikon
- Printing industry
- Industrial electrical engineering
- PLC / PC programming
Xeikon is known in the printing sector as a pioneer of innovative printing technology. Although it is now part of the Flint Group (one of the largest suppliers to the print, packaging and labelling industry worldwide), its digital presses and toners are produced in Belgium. The toner factory has been extensively optimised in recent years. For example, \[…\]
Xeikon is known in the printing sector as a pioneer of innovative printing technology. Although it is now part of the Flint Group (one of the largest suppliers to the print, packaging and labelling industry worldwide), its digital presses and toners are produced in Belgium.
The toner factory has been extensively optimised in recent years. New production lines have been added and outdated machines have been prepared for a digital future. In this case study, we zoom in on the second point.
What exactly did we do to make the toner factory future-proof?
1. Conversion from Siemens S5 to S7-1500:
The outdated Siemens S5 PLC (programmable logic controller) was successfully migrated to the modern S7-1500, and we converted the old code to today's programming language using the advanced TIA (Totally Integrated Automation) Portal.
2. Special connectors for short downtime:
To minimise production downtime, we used specially designed connectors. This meant that not every connection had to be rewired and recabled, saving valuable time during the changeover.
3. Replacement of an old Siemens frequency converter:
The outdated Siemens frequency converter was replaced with the latest G120 model. The old converter was no longer available, which would have caused considerable downtime and problems in the event of a failure. The upgrade ensures reliable and efficient operation of the production line.
4. Digital transformation for MES integration:
Our approach went beyond hardware upgrades. We made sure the renewed system is ready for digital transformation and can be integrated seamlessly with Xeikon's MES. This enables the customer to manage OT data more efficiently and then make better decisions based on real-time information.
5. HMI conversion to WinCC:
The outdated visualisation (HMI) was converted to the modern WinCC platform. The result is an intuitive and user-friendly interface that lets operators carry out their tasks more efficiently.
Conclusion
PLC retrofits are crucial for factories that want to modernise their production, safeguard reliability and prepare for future technological innovations. This optimisation also minimises future downtime and unexpected intervention costs, increases production efficiency and enables smooth integration with digital systems such as MES and SCADA!
