challenge

Meet safety standards and improve productivity to enter new markets

Solution

Guardmaster 440C-CR30- Monitor and guard the interlock switches on the safety gates and emergency stop buttons on the machine, and send real-time messages to the human-machine interface (HMI)
Kinetix 5500 EtherNet/IP Servo Driver - Supports integrated motion control on EtherNet/IP through Studio 5000 software
1769 CompactLogix 5370 Controller - Supports EtherNet/IP Integrated Motion Control
PanelView Plus 7 graphic terminal - built-in Ethernet port to connect machines to enterprise environments
Kinetix TL-Series Servo Motors

achievement

Capacity increased from 70% to 95%
Productivity increased by approximately 30%
Reduce debugging time by about 60%

Taiwan Pulp and Plastic Mold Company, with world leading research and development capabilities and market share

The wave of environmental protection is sweeping across the world, and the public is completely opposed to marine plastic pollution. From tableware, industrial packaging to other industrial applications, all require the use of pulp molding products to replace plastic and polystyrene foam. The demand for pulp molded products and their market potential are growing exponentially.

From obscurity to invisible champion

TPM has nearly 20 years of rich experience in the manufacturing and export of pulp molding machines in Taiwan. From a nobody in the market to a prominent position as an invisible champion in the pulp and plastic molding industry today, the company has been quietly but wholeheartedly committed to global environmental protection over the years.

In 2000, at the beginning of TPM's establishment, Taiwan's pulp and plastic molding industry began to take shape. Environmental awareness is still quite low, and the use of pulp molded products as food and industrial packaging is not common. The company is facing uncertainty in its business prospects. The first three years of the company's operation were difficult. But it wasn't until 2008 that the pulp molding business underwent significant changes. With the continuous awakening of people's environmental awareness and the signing of the Paris Agreement in 2016 with the goal of reducing global greenhouse gas emissions, the world has begun to pay attention to issues such as land and ocean pollution. Developed countries in Europe and America, as well as developing countries such as India, have all begun to develop their environmental protection industries. The plastic hazards in many countries have further accelerated the development of pulp molding business. Orders from around the world are also growing exponentially.

In earlier years, TPM's main export markets were countries with low foreign trade competition and profits, such as Chinese Mainland and Southeast Asia. At that time, the mechanical and electrical control components were mainly Japanese brands, and the trial operation period generally lasted for more than six months. Therefore, entering the European and American markets is very difficult, and expanding overseas business presents numerous challenges.

In order to shorten product development and trial operation time and obtain strict European market access qualifications, TPM has begun to face daunting challenges, including obtaining, comparing, and analyzing safety standards and production data, which are the most important indicators in European and American countries.
Cooperate with American automation giant Rockwell Automation Co., Ltd

After forming a strategic alliance with Rockwell Automation, TPM is able to adopt Rockwell Automation's latest technology, including Guardmaster 440C-CR30 programmable safety relay: monitoring and guarding interlock switches on safety gates and emergency stop buttons on machines, and sending messages to the human-machine interface (HMI) in real-time. The application of Rockwell Automation's safety solutions technology, including the installation of protective nets around hazardous areas, helps machines achieve the PLe safety performance level of CE ISO13849-1 and the R4 risk category of ANSI/RIA R15.06. The machine is also compatible with the highest safety standards in the European and North American markets.
Kinetix 5500 servo driver: Supports integrated motion control on EtherNet/IP through Studio 5000 software. The execution, design simplification, operation, and maintenance of this motion control system can be achieved through a control platform and a network environment. The Kinetix 5500 simplifies wiring operations and reduces inventory pressure with its three in one power cable (feedback, brake motor, and power distribution). To further enhance its design, the Kinetix 5500 is also equipped with two Ethernet ports, which can be used for various topology applications.
The control system is managed by the CompactLogix5370 programmable automation controller (PAC) and can communicate under the EtherNet/IP communication protocol. This provides a connection platform between the production factory and the company's intranet. The CompactLogix 5370 L3 supports EtherNet/IP integrated motion control, device level ring network (DLR) topology, and has built-in power storage devices, eliminating the need for lithium batteries. It supports the reuse of existing 1769 I/O and includes a removable Secure Digital (SD) memory card (1GB), enhancing data integrity. Its flexible memory options can reach up to 3MB, and the non energy storage version (NSE) also has additional hazardous environment features. Supports Kinematics functionality without the need for additional robot controllers and software. Its open socket interface supports Modbus TCP as well as devices such as printers, barcode readers, and servers.
PanelView Plus 7 graphic terminal: Built in Ethernet port can connect the machine to the enterprise environment. ATEX Zone 2/22 and UL Class 1 Zone 2 certifications can be used in hazardous environments. Display and external installation instructions can save 50% -90% of complex display screen development time. The SD card slot can be used for storing, recording data, managing production instructions, and also for quick and easy copying or restoring instructions. The real-time diagnostic system can obtain HMI execution level environmental data, including temperature, load, and battery voltage, thereby accelerating the speed of fault handling.
Studio 5000 automation engineering and design environment software platform integrates motion control: reduces overall production costs, significantly shortens start-up time, mold installation and maintenance time. Security risk assessment, security system certification, and other security services: A professional RA team can identify risks during machine operation, maintenance, installation, and cleaning processes, and then discuss potential risks with TPM for each machine and propose remedial measures to reduce project risks to an acceptable level. After implementing risk reduction reform measures, perform machine safety verification again. The team assists TPM in reviewing and confirming that the machine complies with general or specific machine standards and regulations in Europe, North America, and globally.

Realize economies of scale and improve productivity

The TMP1600 three-stage pulp mold hot press will be used in conjunction with a direct hot pressing system and automatic layering equipment to reduce labor costs and improve production capacity, thereby achieving economies of scale and high-quality products. The in mold drying production process is suitable for large-scale production and widely used in industrial and food packaging production. The machine can provide overall safety protection, and its mold design is easy to disassemble and clean.

The success of this project has set a new milestone for Rockwell Automation in the field of pulp equipment and pulp mold hot press applications. Before the introduction of Rockwell Automation control systems, TPM's machine capacity was only 70%. After implementing the system, the production capacity increased to 95%. Global component replacement has become more convenient, not only helping to drive customer development, but also increasing productivity by about 30% and reducing trial run time by about 60%.