The optimization of individual machine components can significantly increase the productivity of the entire equipment. However, according to the Machinery Directive 2006/42/EC, the generation of high-quality safety concepts often involves risk analysis. As a complete safety automation supplier, Pilz provides a well-known Swiss potato chip manufacturer with support for the integration of new packaging lines: the PSS 4000 automation system helps Zweifel Pomy-Chips AG ensure efficient and transparent equipment safety management.
As the central component of the new packaging line, the PSS 4000 automation system for safety and automation monitors all safety-related functions of Zweifel.
There is a faint smell of potato chips in the air: the production plant covers two floors, is about 200 meters long and is producing at full speed. Zweifel Pomy-Chips AG is located in Spreitenbach (near Zurich) and uses 5 metric tons of potatoes per hour to produce potato chips in various flavors. The company has nearly 400 employees and produces potato chips and various other snacks and snacks. Zweifel always puts innovative production processes to ensure stable and high product quality in the most important position. There is a faint smell of potato chips in the air: the production plant covers two floors, is about 200 meters long and is producing at full speed. Zweifel Pomy-Chips AG is located in Spreitenbach (near Zurich) and uses 5 metric tons of potatoes per hour to produce potato chips in various flavors. The company has nearly 400 employees and produces potato chips and various other snacks and snacks. Zweifel always puts innovative production processes to ensure stable and high product quality in the most important position.
Innovation must have risk assessmentZweifel is modernizing nine packaging lines. In terms of increasing production equipment, the company has always had a wealth of professional knowledge. Therefore, it prefers to be responsible for the planning and expansion of production equipment and equipment programming. Zweifel issued a tender for the necessary packaging conveyor system and specified the equipment control system.
The interconnection between the various equipment parts means that the interfaces and logical connections of the emergency stop function must be evaluated, and overall compliance must be ensured. Therefore, the Machinery Directive 2006/42/EC is required: accordingly, the machinery produced must provide adequate protection for the safety of personnel and the environment. In the bilateral agreement, Switzerland also pledged to comply with this directive. Machinery manufacturers and personnel responsible for product launches must provide a binding certificate showing that their equipment meets the minimum requirements in the form of a compliance statement. Faced with a large number of standards to be considered, in order to ensure security, a certain degree of professional knowledge is actually required.
The complete safety automation supplier Pilz's product portfolio includes a complete set of services, consisting of machinery safety-related consulting, engineering design and training.
Support to obtain CE certification"We are very clear that we need the support of strong partners. We have maintained a good cooperative relationship with Pilz for a long time. We understand that they have professional capabilities in risk assessment and development of reliable safety concepts until CE certification", Zweifel's According to Gerhard Meier, the leader of the technical service team. In order to establish safety-related control concepts, Pilz worked closely with the company. The concept involves the development of mechanical, electrical and other technical engineering solutions with the goal of mechanical safety. The main components of the concept include: the application of standards and directives that comply with the current state of the art, the definition of safety integrity level (SIL) or performance level (PL), as well as machine utilization and productivity considerations, including safety areas. Zweifel was looking for a high-performance safety control system to connect and monitor the exchange of safety-related signals, and the system needed to be independent of or parallel to the equipment control system. The requirements mainly include: the equipment should be highly networked, reliable and easy to program, and easy to use in daily operations.
Pneumatic control flap, controlled by PSS4000
The air control flap is opened to let the potato chips enter the automatic packaging machine.
Traditional automation solutions use an independent centralized control system to monitor equipment or machines and process all signals, but the PSS 4000 automation system can realize uninterrupted discrete control functions.
Zweifel conveyor belt grooves transport the baked potato chips to the new packaging line. The air control flap is opened to let the potato chips enter the automatic packaging machine. The potato chips are immediately put into the packaging bag and placed in a standard shipping box on the market. The company previously used Pilz's PNOZmulti programmable control system to be responsible for the safety management of the equipment. However, the larger the equipment, the more complex the requirements. Therefore, systems such as PSS 4000 become more efficient and economical complete modular systems. This is because the system also provides options that combine and actually integrate safety and automation. “We were very concerned about the development and launch of the PSS 4000 automation system. After conducting an internal cost/benefit analysis of the two systems, we concluded that now is the right time to adopt the PSS 4000,†said Gerhard Meier.
Pilz's PSENmag magnetic safety switch is used for position monitoring.
Overall safety managementAs the central component of the new packaging line, the PSS 4000 automation system for safety and automation monitors all safety-related functions: the packaging line includes safety gates and smart access concepts. The safety door is equipped with Pilz's PSENmag magnetic safety switch and PSENcode coded safety switch. The latter is used to monitor the position of guards in accordance with EN 60947-5-3 and can also be used to simplify position monitoring. The cylinder is also monitored for safety: the flap must be safely locked during cleaning, otherwise the risk of injury will increase. The emergency stop button is located near the packaging line and is also monitored by the automation system. The company attaches great importance to the construction of four independent safety circuits. They must ensure that the user can finally clean a part of the device without stopping the entire device. The PSS 4000 automation system for safety and automation generally represents the best interaction between hardware and software components, network equipment and real-time Ethernet. Since control functions can be continuously allocated and transferred to peripheral devices, compared with traditional solutions, this system can be used to implement large-scale projects more easily and flexibly. Instead of using a centralized control system, a modular user program is provided in a centralized project. This method supports standardized simple loading and unloading. With the ability to undertake security and automation tasks, the automation system has proven its value in many applications in various industrial fields.
Simple and transparent parameter setting"When selecting the PSS 4000 automation system, the decisive factors included simplicity, significantly reduced wiring work, clear communication, clear responsibilities, and ultimately high cost-effectiveness," said Gerhard Meier. The communication between the equipment control system and the existing Modbus TCP bus system is proceeding smoothly. Another key decisive factor in choosing this automation system is the ability of the PAS4000 software platform and its graphical editor to connect to the existing structure of the PNOZmulTI Configurator, so future parameter settings will remain transparent and simple.
Zweifel launched the joint packaging line project in the fall of 2012; the factory was put into operation at the end of 2013. "As always, we have cooperated with Pilz in a spirit of cooperation. Pilz not only supplied us with quality products, but also provided us with strong written and action support before, during and after commissioning," Gerhard Meier concluded. Zweifel will undoubtedly launch more projects and the prospects are very bright.
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