Inspec.Tech’s innovative inspection system provides a ‘smart’ solution that helps companies boost their productivity by continuously and accurately monitoring pellets during the extrusion process.
With no mechanical components, this system is designed for easy integration into existing extrusion lines. Thanks to its compact size and user-friendly interface, it can be quickly and efficiently installed with minimal disruption to production.
The system can automatically and continuously detect impurities in pellets at a rate of approximately 9 tons per hour, as well as variations in contour, size, and color. Not only is this data collected and recorded, but it can also be used to sort off-spec pellets at a rate of up to 3 tons per hour while generating targeted alerts and warnings. This allows operators to gain real-time insight into the current performance of their production compared to a pre-defined ‘golden reference.’
This continuous monitoring ensures that production stays within specifications, providing an instant overview of which machines are performing well, where faults are occurring, and whether delivery times will be met.
Inspec.Tech’s in-line and real-time pellet inspection system can seamlessly integrate with Manufacturing Execution System (MES) software, which is crucial for achieving an efficient and optimized production process. MES software provides valuable information that enables decision-makers to better manage and optimize their production processes, regardless of scale.
For extrusion companies bound by strict traceability requirements, this combination is ideal as it supports compliance with quality standards while ensuring thorough documentation of the production process.
With the inspection system, production orders can be logged simultaneously across multiple parameters, such as contamination, black spots, pellet size, pellet shape, tails, and color variation. Off-spec pellets are sorted immediately, ensuring that the production process remains within specifications. Additionally, the system eliminates the subjectivity of human assessment by presenting factual data, leading to a more controllable process and improved product quality.
In addition to its technological advantages, the Inspec.Tech system helps reduce workload, or psychosocial work stress (PSA), by stabilizing processes and minimizing disruptions. When production runs smoothly, operators no longer need to constantly worry about meeting deadlines, reducing stress and frustration.
The stability of the process leads to a higher quality product and results in fewer disruptions, lower workload, and cost savings. The combination of MES software and the inspec.tech inspection system ensures clearer planning and allows operators to focus on maximizing their talents instead of constantly firefighting.
With Inspec.Tech’s advanced vision technology, companies can monitor their extrusion lines second by second. This provides crucial information on machine performance, output, and loss rates. When tolerances begin to drift, adjustments can be made immediately to stay within required limits.
This enables companies to identify and eliminate the root causes of recurring issues. Moreover, maintenance intervals can be adjusted based on detailed data, leading to an even more precise and efficient production process.
Another key feature of the inspec.tech system is its continuous control and traceability of quality. In the event of a complaint or incident, the collected data can precisely pinpoint where the problem originated. As long as process data remains within control limits and specifications, the product quality remains consistent.
The data can also be shared with customers to demonstrate process stability and reliability, helping to build customer trust and, in some cases, proving that an issue may lie on the customer’s side.
To gain a better understanding of how the inspec.tech in-line and real-time pellet inspection system works and how it can enhance production processes, you can watch our demonstration video on YouTube. This video clearly illustrates the functionality and benefits of the system, giving plastic manufacturers valuable insights into how they can optimize their processes.
Conclusion
In an era where technological advancements are moving fast and companies are pressured to produce more efficiently and effectively, staying connected with the latest innovations is critical. Inspec.Tech’s in-line and real-time pellet inspection system not only enables plastic manufacturers to ensure product quality, but also to optimize their production processes. By embracing this technology and integrating it with MES software, companies can strengthen their competitive position, reduce operator workload, and be better prepared to face the challenges of the future.
Invitation for a test with your own product
Are you curious about how the Inspec.Tech in-line and real-time pellet inspection system can improve your production processes? See the power of continuous monitoring in action and discover firsthand how our technology works in practice.
We offer the possibility to test the system with your own product so you can experience directly how it can optimize your production and ensure product quality. Contact SPS | Solids Process Solutions, partner of Inspec.Tech within the Benelux, today for more information or to schedule an appointment!
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