Your first step to a smart coating line

ModEX

Transparency and automation are among the key drivers for any production facility nowadays. Being able to collect all production-relevant data from the production lines, allows every company to gain a detailed understanding of the potential for process improvements.

A coating line with multiple machines offers a diversity of possibilities for cost savings. Smart and automated connections between the machines can help to achieve this. The modular exchange system ModEX from Koenig & Bauer MetalPrint presents new opportunities for the networked and automated operation of coating lines.

Modularity for maximum

As the demands and ideas regarding digitalisation and automation differ from customer to customer, ModEX is designed as a fully modular system. This means the customer can decide which exact functionality he wants to use. At the same time, it is possible to add additional modules at a later stage. This allows the customer to grow and learn with the new possibilities ModEX has to offer.

Base module

The foundation is the so-called ModEX base module, which enables all individual machines used in a coating line to connect with the customer MES, PPS or MIS system. The necessary interface follows the OPC-UA standard, a common, industry-wide interface for machine networking. The coating line is provided with an OPC-UA server, which is additionally secured with an integrated firewall to separate the machine network from the shop floor or customer network. With this technology, each machine is now able to supply machine status information, fault messages and parameter values to the customer system in real time. With the base module, the communication between coating line and customer system is uni-directional.

Data exchange with the customer system

With the ModEX Data Exchange module (DEM), ModEX establishes bidirectional communication with the customer system. This allows ModEX to receive advance information about the next production job. This job information can include various parameters, such as:

  • Sheet format
  • Sheet thickness
  • Production number
  • Job number
  • Oven temperature
  • Fan frequencies
  • Number of sheets overall
  • Number of sheets per pallet

All the information for the next job is sent from the customer system to ModEX shortly before the job start. In addition to the information from the base module (status information, fault messages, parameter values), the data exchange module passes much more information back to the customer system. This includes:

  • Sheets per pallet
  • Pallet ID
  • Overall number of sheets
  • Gas consumption
  • Oven temperatures recorded during production

All information is sent to the customer system automatically at the end of each job. The operator can focus on the actual production, as ModEX provides all relevant information fully automatically.

Cost reductions through automation

One of the biggest cost factors in production is still the operator. It is thus no surprise that robot technologies and camera-based systems are on the rise as means to support the operator and to accelerate processes. ModEX brings this form of automation to coating lines. The benefits begin with automatic starting and stopping of production in accordance with the specified run length, information which is conveyed to ModEX from the customer system. In other words, ModEX stops the sheet feeder as soon as the required number of sheets has been fed to the production line. If a double or triple stacker is installed, ModEX even switches the active box as soon as the desired quantity per pallet is reached. The number of coated sheets actually produced is now not dependent on the operator. Assuming an annual production of 5,000 jobs and a sheet cost of one euro, the savings already amount to €50,000 ($55,000) per year if the operator no longer produces 10 sheets more than is actually necessary for each job. The makeready of a coating line includes processes such as the conversion of various machine components to new parameters or the documentation of production data. As ModEX performs these tasks automatically via the communication with the customer system, the operator can save time and increases the available production time per year. Taking the same example of 5,000 jobs, a time saving of 5 minutes per job helps to reduce costs by more than €100,000 ($110,000) per year.

A smart and networked line

As all machines in the production line are connected to ModEX, the state of each machine is known to the system at any time and is also displayed on the ModEX operator screen. The overview shows which job is now on which part of the line, and which parameters are set on the corresponding machine. With this information, ModEX is now able to complete makeready processes without operator interaction. Example: Job 1 is current being coated. The required temperature in the heating zone is 200°C. The next job planned by the MES is Job 2, which requires a heating zone temperature of 210°C. ModEX will now automatically trigger the temperature rise as soon as the last sheet of Job 1 leaves the heating zone, so as not to lose time during the makeready process. Again, all without operator intervention and the possible delay for manual actions. With such technology, the vision of a smart, self-adjusting line comes even closer.

Screenshot: Line overview with current job numbers, product numbers and loaded parameters

Basis for future developments

ModEX represents the start of a new automation and digitalisation strategy from Koenig & Bauer MetalPrint. Further ModEX modules are currently at the development and design stages and promise constant expansion of the range of possible functionalities and upgrades. ModEX is available for all new coating and printing lines. Retrofits are also possible upon request.

Damian Pollok

Background photos: The modular exchange system ModEX presents new opportunities for the smart operation of coating lines.