Complete Modernization of a Kroenert RECO Coating and Laminating Line
Customer
Novolex
Project type
Electrical modernization
Year
2023-2024
Project scope
$2,100,000
Project description
To ensure the long-term sustainability of its converting and packaging operations, Novolex undertook the complete modernization of a 1990s-era Kroenert RECO coating and laminating line whose critical components had become obsolete. After decades of service, the equipment presented significant challenges related to spare parts availability, production performance, and control system reliability.
The mandate awarded to Egzatek was to design and deliver a complete modernization solution capable of extending the useful life of this unique production line while integrating current industrial technologies. The project included replacing the Siemens S7-400 PLC with a Siemens S7-1500 platform, migrating communication networks to Profinet, replacing operator interfaces, and modernizing the drive systems.
In parallel, legacy ABB drives and several DC motors were replaced with more modern technologies, including AC motors and next-generation ABB drives, to improve reliability, maintainability, and spare parts availability. The project also included the installation of new cable trays, replacement of numerous motor cables, and fabrication of new control panels compliant with current industrial standards.
Particular attention was paid to minimizing downtime through a phased execution strategy that included preparation, prefabrication, and staged installation activities. This approach reduced the risks associated with the technology migration while maintaining existing production performance and process functionality.
Key work completed
- Complete analysis of equipment and obsolete components.
- Design of a next-generation control and automation architecture.
- Replacement of the Siemens S7-400 PLC with a Siemens S7-1500 platform.
- Migration of industrial networks to a Profinet architecture.
- Modernization of operator interfaces through installation of a new industrial touchscreen.
- Replacement of 25 variable-frequency drives and upgrade of drive systems to next-generation ABB ACS880 drives.
- Conversion of several DC motors to AC motors.
- Manufacturing and installation of new electrical panels compliant with current standards.
- Installation of new cable trays and replacement of motor cables.
- Modernization of machine safety functions, including emergency stops and safety I/O.
- Programming, validation, FAT testing, and site commissioning.
- Technical documentation, functional validation, and operational support.
The operational impact
This modernization is intended to eliminate obsolescence risks associated with control systems and electrical equipment while improving the overall reliability of the production line. Replacing technologies that had become difficult to support is expected to significantly reduce the risk of unplanned downtime caused by equipment failures or unavailable spare parts.
The implementation of a modern, standardized control architecture also simplifies diagnostics, maintenance, and future equipment upgrades. The use of widely available industrial components ensures improved spare parts availability and long-term technical support.
Replacing legacy drives and motors with higher-performance technologies is expected to improve process stability, web tension control, and production repeatability. These improvements help maintain product quality while increasing overall operational robustness.
Finally, the modernization of safety systems and electrical infrastructure aligns the equipment with current industrial standards while providing a technological platform capable of supporting production requirements for many years to come.
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