Automation and advanced digitisation for the rubber calendering process in the tyre industry
Integrated PCS, IIoT and traceability solution to improve efficiency, safety and quality control in tyre inner liner production
O&M Solutions
Righi has developed and implemented an integrated automation and digitalisation project for the rubber calendering plant in Slatina (Romania), specialised in the production of tyre inner liners. The intervention involved the design and implementation of an advanced PCS (Process Control System) with complete automation of recipe management and exhaustive traceability of every single reel produced. The solution was enhanced by the integration of IIoT technologies for real-time monitoring, centralised alarm management and remote control of the plants.
Thanks to digitisation, a centralised and structured storage of process data was realised, perfectly integrated with the company’s management system, contributing significantly to improving operational efficiency, reducing downtime and increasing plant safety.
Challenge
The plant required automated and precise management of the material selection and calendering processes, with full traceability of each production step and the possibility of remote control. It was essential to guarantee the quality and conformity of the materials, reduce downtime and minimise operating errors, through a system capable of integrating data from field sensors, PLCs and SCADA, with alarm management and automatic stops in the event of anomalies. Synchronisation with the management system for orders and planning was essential to optimise production and logistics flows.
Results/benefits achieved by the customer
- Full automation of the calendering process with automatic recipe management via PCS
- Total traceability of the rolls produced, with printing, labelling and data storage in an integrated database on the HMI
- Implementation of IIoT solutions for centralised data collection, real-time monitoring and remote control of production lines
- Automatic extruder shutdown in case of alarms or non-conforming materials, ensuring operational safety and reliability
- Significant reduction in machine downtime and operational errors thanks to the automation of material and recipe management
- Full integration with management systems for production planning and order management, improving logistics flows
- End-to-end technical and engineering support, including remote after-sales assistance
