Case Study: Automation Helps Pulp Molding Equipment Manufacturer to Enter into Global Market
Environmental protection has become serious concern worldwide. And Plastic pollution is one of the important issues that is hurting ecosystem. We use plastic made things on huge scale in our daily life. Many countries have banned plastic use and many are planning to do it. Everything right from cutlery, industrial packaging to other industrial applications need replacement of plastics and styrofoam with pulp molding. The rising demand and great market potential for pulp molding is witnessing an exponential growth these years.
Taiwan Pulp Molding (TPM) has about 20-year experience of manufacturing pulp molding machines and export business. In 2000, when TPM was founded, Taiwan's pulp molding was also at primary stage. The environmental awareness was also quite low, and pulp molded products were also not in use.
In the early days, TPM used to export in the countries with lower foreign trade competitiveness and margins such as Mainland China and Southeast Asia. At that time, the mechanical electrical control components were made by primarily Japanese brands, and pilot run period mostly lasted for approximately six months. Because of these reasons, it was difficult for TPM to make entry into the American and European Market and this made its expansion more challenging.
TPM started to focus on safety standards and acquisition, comparison, and analysis of production data to reduce the product development & pilot run period, and obtain the stringent qualifications to enter into the European and American market.
To implement the technological solutions, Taiwan Pulp Molding formed a strategic alliance with Rockwell Automation. Rockwell Automation is a American company that provides industrial solutions with automation and Information Technology.
Solutions provided to TPM by Rockwell Automation include:
Guardmaster 440C-CR30 – This solution helps to maintain safety as it monitors the inter-locking switch on the guard gate as well as emergency stop button on the machine. This solution also sends a message to Human Machine Interface (HMI) immediately.
Kinetix 5500 EtherNet/IP Servo Drives – This solution supports an integrated motion control on EtherNet/IP through the Studio 5000 software support. Kinetix 5500 helps to simplify the wiring operations and reduce pressures of inventory with three-in-one power cable—feedback, brake motor, and power distribution.
PanelView Plus 7 Graphic Terminals – It has built-in Ethernet port that allows machine connection to the corporate environment. The display and external mount commands are able to save 50%–90% of the complex screen development time. Its SD card slot stores and records data, manages production command, and able to copy or redo commands. The instant diagnostic system can easily acquire the HMI execution level environment data including load, battery voltage, and temperature for accelerated troubleshooting.
The solution not only simplifies manpower but also improves capacity, resulted in high quality products and economies of scale. Production with Dry-in-Mold process has capacity for mass production and is used in production of industrial and food packaging on a wide range. The machines provide safe protection and its mold designs allow easy cleaning. Before the implementation of the Rockwell Automation control system, machine yield for TPM was only about 70% but now it has increased to 95%. It has also allowed for convenient component replacements around the world which helps to drive customer growth while increasing productivity by approx. 30% and reducing the pilot run period by around 60%.
Neha writes articles on sectors including medicine, food, materials, and science & technology. A qualified statistician, she has the ability to observe and analyze the trends in global markets and write compelling articles that help CXOs in decision making. She is a bookworm and loves to read fiction, lifestyle, science and technology. Neha comes with 6 years of experience in content writing and editing that involves blog writing, preparation of study materials and OERs.