NPE 2015 Wrap-Up
Knowledge Center Supplement
September 2015
The Shows
Within The Show
NPE Wrap Up
• NPE New Product Recaps
• Guide to Energy Saving Drying
• Central vs. Press Side Installation Guide
• New Predictive Maintenance Products
for Processors
Sponsored Content
NPE 2015 Wrap Up–The Shows Within a Show
Easiest to Use
Mobile Wheel Dryers
CONTENTS
4............... How to Pick Press-Side vs. Central in
Drying and Conveying
10.............. How to Save Energy with Dryer Installations
12.............. NPE Update on Intuitive Dryer Controls
Standard Dry Air
Conveying Package
Standard LED
Alarm Light...Matsui
Charges Over $250!
Just Enter Your Polymer Type
and the Smart Control PLC
Does the Rest…
What Good is a Mobile
Dryer if You Don’t
Know the Dewpoint?
We Include It. Matsui
Charges an Extra $900!
14.............. Tips to Improve Dryer Performance
18.............. NPE Update on New Downstream Extrusion Products
22.............. Minimizing Conveying Maintenance Through
Pellet Speed Control
31.............. NPE Update on New Resin Conveying Products
33.............. Predictive Maintenance Platform for
Conveying Pumps and Dryers
37.............. New Prophecy Products for Plastics Processors
Exclusive Overdry
Protection Ideal for
Nylon and Other
Sensitive Materials
Very Smart Upgraded
Software Senses Faults…
Automatically Tells You
When to Change Filters
Standard Conveying
Blower Package
Need More Answers?
Go online to www.ptonline.com and click KNOWLEDGE CENTERS
Best Practices, Cost Saving
Tips, Product Technology
Pictorially Guides
You in a Solution
Built-in Standards...
Sold as Options Everywhere Else!
www.novatec.com/dryers
Comprehensive collection of
technical content
On-Demand Videos &
Webinars
The latest technology in action and
explained by industry experts
Ask Experts
Connect with industry leaders for
immediate answers
Visit our five Knowledge Centers for detailed
information on each of these critical areas:
DRYING
CONVEYING
DOWNSTREAM
EXTRUSION
PREDICTIVE
MAINTENANCE
BLENDING
www.ptonline.com
Standard 5-Year Warranty | Made in the USA | 800-237-8379 | www.novatec.com
© Copyright 2015 Novatec, Inc.
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 3
NPE2015 Wrap Up |
DRYING
Press-Side vs. Central Drying
How to Select Whether Press-Side or
Central Drying Works Best for Your
Processing Location.
There are, of course, reasons why pressside dryers may be best for some processors
but more and more are converting to central
systems because their production requirements
have changed over the years. Once they make
that change, they will never go back because the
economic advantages of a central system are very
favorable to most processors profit margins.
Let’s examine:
•
Reasons for maintaining a press-side
arrangement
•
Reasons for considering a Central
Drying System
•
Economic benefits of a Central
Drying System
Press-side or press-mounted dryers are
commonplace where processors have fewer than
10 process machines and have low throughputs
on those machines (under 25 lb./hr.). It also helps
if the processor is running the same material on
the same machine day-after-day, making very
few material changes. This requires that there be
a vacuum loader at each machine and a source
of material (usually a bulk box or drum of resin).
Processors learn to live with fork lifts delivering
material to the presses. Note that if access is
ever required to the machine throat, the dryer and
loader have to be removed, then re-mounted. Still,
this arrangement seems to work for this group of
processors.
4 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
Small press –
mounted dryer
for medical
application
Portable Dry/
Convey Model
The interim move to a Central System for most
processors is to introduce multiple portable dry/
convey units. These dryers are usually mounted on
a cart with a drying hopper, a loader or receiver to
supply resin to the drying hopper and a machinemount loader or receiver to deliver material to
the machine throat. The throughputs range up to
about 300 lb./hr. The bulk boxes and forklifts are
still present – clogging up the production area. If
multiple material changes are required, processors
often have extra dry/convey units in an area off the
production floor that can be wheeled into place
beside the process machine. This adds to the
confusion on the production floor and the whole
process often results in material being left in the
bulk bins and or contaminated and simply wasted.
Yet another scenario occurs when a processor
needs higher throughputs than 300 lb./hr. and
larger stationary dryers are introduced to the
production floor – taking up even more floor
space. Or, worse yet, they will be mounted
on racks above process machines. In these
cases, routine maintenance will probably not
be performed – ultimately resulting in excessive
rejected parts and higher energy bills.
It should be noted that even when you are
drying the same material in different dryers (even
of the same model) you may experience variation
in the levels of drying. Differences in the age of the
desiccant, heaters, blowers or even condition of
the filters may cause this.
often have more than one central dryer – each
serving a bank of hoppers with a back-up central
dryer for times when a dryer may be taken offline
for maintenance.
YOU ARE A GOOD CANDIDATE FOR
CENTRAL DRYING/CONVEYING IF…
•
•
•
•
•
•
•
•
•
•
ou have dryers on 10 or more machines
Y
You have a single material that requires
drying at multiple machines
You have frequent material changes on
your machines
You use more material types than you
have machines
You have dryer to dryer quality issues
when drying the same material
You want to expand, but do not have
sufficient space
You need flexibility to serve the needs of
your customers
You have a Just-in-Time objective to
reduce inventory
You need to reduce operating costs
You want to improve safety for
your workers
WHAT IS CENTRAL DRYING?
Dryer Mounted
Above Press
Central Drying allows one dryer to provide
-40°dew point air to multiple material hoppers of
different sizes. An adjustable heater and blower
are mounted on each hopper so the heat and air
flow can be adjusted to the material in that hopper.
So you have custom drying of multiple materials
from a single central dryer that is sized to match
the requirements of that bank of hoppers. Central
Dryers are available with throughputs from <200
lb./hr. through 5,000 lb./hr. so a wide range of
processor needs can be easily met. Processors
Compact Drying, Blending and Conveying area
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 5
Press-Side vs. Central Drying
WHAT ARE THE BENEFITS OF
CENTRAL DRYING?
We will discuss specific savings but here is an
overview of benefits:
•
Space savings
•
Fewer materials handlers
•
Energy savings (Rebates often available)
•
Increased machine uptime (no waiting for
material to pre-dry)
•
Material control reduces waste (small
inventory to clean)
•
Improved product quality (drying consistency through your plant)
•
Fast payback of investment (because
there are multiple sources for savings)
ADDITIONAL SAVINGS NOT CALCULATED:
•
•
Unclog your production floor
aintenance on 12 dryers vs. 1 Central
M
Dryer
Brush changes & filter cleaning for 12
loaders vs. just filter cleaning for 12
vacuum receivers
•
•
nergy usage for 12 dryers and 12
E
loaders vs. 1 dryer and 1 vacuum pump
Loss of material due to bulk box
movement, material contamination and
poorly made parts
On this point, let’s assume that 10 lb. of material is lost per bulk box and that is not unusual…
Yearly Costs:
Press-Side
Cost/Year
Yearly Costs:
NOTE: These figures were not picked out of the air! They are based on typical results of before and after
plant surveys of processors who moved from press-side drying to a Central Drying/Conveying System.
Based on 12 machines – Average throughput 200 pph - Drying Nylon/ABS/PC
Press-Side
Cost/Year
Example:
Central Dry/
Convey Cost/Year
Energy Costs:
Press-Side–$.10/kwh x 11 kw x 8,000 hr./yr. x 12 dryers
12 x 3 = 36 x 10 lb. X 50wks. - 18,000 lb. /yr.
ABS - 18,000 x $0.74/lb. =
$13,320
PC Injection, General Purpose - 18,000 x $1.90/lb. =
$34,200
PC – Flame Retardant – 18,000 x $2.42/lb. =
$43,560
And how about the wrong material being processed?
Has that happened at your plant?
$108,000
Central–$ 10.kwh x 51 kw x 8,000 hr./yr. x 1 dryer =
12 Press-Side Dryers – 3 changes/wk./press
$41,000
Add: Cleanup, disposal and lost machine time and you can
easily triple these costs.
Material Changes: Press-side dryers require 30 minutes to 4 or 5 hours for material changeover.
Press Side–
Based on 2 hr. average x 3 changes/machine/week x $50/hr.
$180,000
Central–
Based on .25 hr. average x 3 changes/machine/week x $50/hr.
$22,500
Labor:
Central Conveying typically eliminates at least one
material handler/12 machines.
$ 30,000
$0.00
$318,000/yr.
LET’S TALK ABOUT SPACE!
Typically, a processor using press-side dryers has to allow and extra 75 sq.ft. per process machine for
a dryer, hopper and bulk box. Now add the space required for a fork lift to maneuver in, haul the old bulk
box away and replaced it with a new one…suddenly, you are up to about 120 sq. ft.! Multiply that by the
number of presses you have and you will see how many additional presses you can fit into that space –
that, after all, is supposed to be your manufacturing area – where profits are made.
$63,500/yr.
Central Drying/Conveying Savings: $254,500 /Year – EVERY YEAR!
24 Machine plant: $509,000 Savings/Year! • 36 Machine plant: $763,000 Savings/Year!
6 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 7
Press-Side vs. Central Drying
CENTRAL CONVEYING –
ADDS BENEFITS TO CENTRAL DRYING!
Reduced Material Costs - Central conveying
may allow you the option of buying materials in
bulk for silo storage with a “free” silo from your
material supplier or you may be able to increase
your purchases to a point where it is advantageous
to use bulk bins for storage instead of those pecky
bulk boxes. But, even if you have to continue
with bulk boxes, for some reason, they can at
least be stored in a designated area where one
person is responsible for ensuring that the material
remaining in the liners is emptied into the new
container and they are properly covered to prevent
contamination.
Quick and Correct Material Changes Central conveying is the reason that material
changes can be reduced to about 15 minutes and
with Auto ID validation of materials, you can be
sure that the right material will always go to the
correct machine.
Central Drying/Conveying improves process flow and reduces costs.
Need Help Making a
Decision About Converting
to a Central System?
Auto ID validation eliminates molding the wrong material
Safety – Reduced material spillage means
safer conditions on the production floor.
A Central Drying/Conveying System can pull
materials from a combination of silos, bulk bins
and bulk boxes to drying hoppers, or blenders or a
combination of those.
8 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
Jim Zinski
[email protected]
443-457-1379
Ask for a plant survey to determine whether, and how much, you can save on energy
costs, wasted materials, reduced rejects, labor, maintenance and increased up-time.
The usual payback time is 12-18 months so the sooner you act, the sooner you start saving.
Bulk Purchases reduce resin costs
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 9
NPE2015 Wrap Up |
DRYING
Energy Saving Drying Tips
Energy costs are one of the few things
you can control.
You can exert some control over those
monthly energy cost whether you continue to
use existing dryers or you are planning to replace
existing dryers.
Let’s examine your existing dryers and
hoppers first: Maintenance, maintenance,
maintenance!
Clogged filters increase
energy consumption
•
•
be required to sign a checklist (like you
see in restrooms) when they perform the
cleaning. You should also keep replacement filters in stock for each dryer. Newer
dryers use pressure drop indication to
alarm when filters need attention.
Plasticizer Filter and Drain – It is
equally important that plasticizer filters
be cleaned on a regular basis and excess
plasticizer be drained to ensure that
contaminants do not get into your desiccant – which will cause it to lose effectiveness and require early replacement.
Differential pressure
switches can warn of
filter clogging
rocess & Regeneration Filters - Do
P
you realize how much dirty process and
regen filters can reduce the efficiency of
your dryers? Would you believe a 30-40%
reduction in efficiency? That means you
are using a lot much more energy to
dry your materials or – your percentage
of rejected product is increasing. Most
older dryers do not provide an alarm
when filters are clogged so it is imperative that a regular cleaning schedule be
established and followed by production
personnel. The schedule should be
based on the dustiness of the material
being processed and operators should
10 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
Drain plasticizer and wash filter regularly
•
heck and Replace Desiccant – Poorly
C
performing desiccant can also increase
energy usage because it does not absorb
moisture as readily as it should nor
does it regenerate as quickly so process
Worn out desiccant
beads cause higher
energy costs
times increase – using more energy or
poor product is produced which also
represents wasted energy. A good sign
of ineffective desiccant is when the dryer
is not consistently producing -40°D dew
point process air. One of the easiest
ways to check desiccant is visually. If it
is discolored – replace it. Also, grab a
handful of desiccant of cool desiccant
and squeeze it…you should feel it warm
up quickly – without crumbling.
•
Hose and Hose Connections – Every
few months, all hose clamps should be
checked for tightness and all hose should
be examined for holes and cuts in and
around the dryer and at the hopper. Air
leaking from these points represents
energy flying off into the air.
•
Hose Insulation – Be sure that all hoses
that carry hot air are well wrapped with
insulation. Note that the process return
air hose from the hopper to the dryer
should not be insulated.
•
If the dryer is not attaining the proper
process and regeneration temperatures,
it could be a sign that a heater needs to
be replaced. Any delay, means that poor
parts are probably being produced.
Every poor part that is produced represents
wasted energy, labor and higher material cost.
Now let’s look at energy considerations for
new dryers and hoppers:
First and foremost, when replacing an old
dryer, talk to suppliers who offer more than one or
two types of dryers. If all they have to sell are Type
1 and Type 2 Dryers, they will try to pigeonhole you
into one of those. Today, you have many choices
and you can find the type best-suited for each
application you have.
Just like energy usage has been reduced for
home appliances and automobiles, energy usage
has been reduced for newer types of dryers while
older dryer types have lagged in energy-saving
features.
Dryers:
•Compare energy usage for the typed of
dryers that meet your processing requirements. Any manufacturer you talk to
should be able to show you the kw/lb. or
kw/kg of material processed so you can
relate that to your cost/kw in your area.
•Ask whether the dryer control includes
any special energy-saving features – see
article on Dryer Controls.
•Make sure that high temperature hose or
ducting is well-insulated.
•Ask whether the dryer you are considering qualifies for an energy-savings
credit.
Hoppers:
•A minimum of 2” of insulation should
be sandwiched
between the walls
of the hopper cone,
hopper door and
hopper sides, but
not in the section
where the return air
exits the hopper.
You want relatively
low-temperature air
Hopper insulation
to be returning.
should extend from
Placement of Process
bottom of cone to
Heater: This depends largely just below process
on the size of the dryer.
return outlet.
•For smaller dryers,
the process heater is usually in the dryer
when the hopper is very nearby.
•For larger systems, where the hopper is
several feet from the dryer, the process
heater should be mounted on the hopper
to minimize heat loss.
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 11
New Product Recap:
Intuitive Dryer Controls
NEW CONTROLS AND SOFTWARE
FOR MOBILE DRYING
Novatec’s mobile dry/convey systems, used for
beside the press drying operations, was one of the
most popular attractions at NPE. These modular
carts can be equipped as stand-alone dryers
or equipped with an integral hopper/conveying
package as shown. Sizes for these wheeled
models are available from 25 lbs./hr. to 400 lbs./
hr. and are all featured with standard color touchscreen HMI with PLC controls. “Plus” models
feature a 7” HMI with over-dry protection while
standard models come with 4” color. All models
are now equipped with Novatec’s advanced
high-definition software which provides complete
control over the dryer, the hopper, and receivers
within the system. Complete onboard drying
system diagnosis and trending is included within
the standard package.
NEW CONTROL AND SOFTWARE
FOR CENTRAL DRYING
Novatec central dryers not only control
drying parameters at the dryer, including energy
optimization, but also have the ability to control
operations of up to 12 hoppers. These dryers
come complete with self-diagnostics and troubleshooting alarms. The alarms utilize easy to understand language and if something is not understood
the operator simply presses the screen for more
detailed explanations. The larger central dryers
also come with standard variable frequency drive
for the regeneration blower.
Novatec’s new central drying software includes
standard drying optimization controls. This
ensures that the resin is exposed to the specified
levels of heat and dryer air without the danger of
under-drying or over-drying , which leads to either
excessive energy use and/or improperly formed
parts. These systems provide the capability of
controlling, trending and monitoring the dew point,
drying temperature and pre-drying time as well
as the temperature and dew point limits on each
hopper in the central system.
UPDATED LOCAL CONTROL HOPPER
TECHNOLOGY SHOWN AT NPE
Novatec’s central drying hoppers, with new
advanced controls, allow easy entry of drying
temperatures plus high and low set points.
Options include a dew point display, or a dew
point display plus patented moisture manager
software, to carefully control the drying process.
This feature can be particularly useful for moisture
sensitive resins such as nylon where under-drying
or over-drying can result in loss of physical properties and defects in final products.
Standard Central Drying Hopper includes
control of drying temperature plus high and
low set points and a hopper with greater
energy efficiency. Control options provide
either dew point display or a combination of
dew point display and the patented Moisture
Manager software that closely controls
moisture content.
12 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 13
NPE2015 Wrap Up |
DRYING
Always have an extra set of clean filters
ready for changing. It’s never a convenient
time to shut down the dryer to clean and
change the filters but operation of the dryer
without filters, even for a short period, can
allow plastic dust to get into the heater and
can lead to destroying the desiccant or
even a fire.
Haynie’s Dozen Drying Tips
2
We call Mark Haynie, “The Drying
Doc”. Mark Haynie has almost 40
years experience in dryer and desiccant
design for plastics and industrial
applications. He has helped many
processors achieve improved drying
performance throughout by consulting
with them and understanding their
specific drying issues.
Proper maintenance is a key to having your
dryer perform to your expectations. Also, dryers
need to be equipped differently depending on
the resin you are processing and the required
drying temperature, high (225°-300°+ F) or low
(below225° F). Here are some factors you should
consider to ensure that the dryer performance
meets the requirements of the resins you
are processing.
1
onitor Dew Point
M
The dew point produced by a dryer is not
directly tied to the dryness of the resin, but
rather the dryness of the air produced by the
dryer. However, knowing the dew point can
tell you that the dryer is probably operating
up to its specifications. The dryer should have
continuous monitoring of the dew point to
help you in determining if it’s fit for the job.
14 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
Monitor Air Flow
Proper air flow is important. It is both the
vehicle that provides the low dew point air for
drying of the resin and it carries the heat from
the process heater to the resin. The best
practice is to have a continuous monitor –
typically a pressure drop device –which gives
a warning when air flow is reduced.
4
5
Monitoring Current Flow and
Inspecting Filters
Monitoring Current
Flow
3
Inspecting
Filters
eep Air Filters Clean
K
There are filters in both the process and
regeneration air streams. The filters should
be checked frequently (every 2 weeks) and
onitor the Return Air
M
Temperature to the Desiccant
Molecular sieve desiccant dries the process
air best at low temperatures. When the
temperature of the air returning to the
desiccant bed exceeds 140-150° F the dryer
will not achieve a -40° F/C dew point. If the
return air temperature is exceeding this level,
then there is too much process air or too high
a processing temperature. A thermocouple or
temperature indicator, at this point will let you
know this. In some modern systems, this
temperature is fed back into the controls so
that a VFD (variable frequency drive) can
change the air flow rate automatically.
Maintaining a return air temperature of
140-150° F also minimizes energy usage.
ake Precautions for
T
Low Temperature Drying
Drying temperatures lower than 160-170 F are
difficult to achieve for most standard dryers.
These temperatures apply to some nylons,
co-polyesters, PLA and a few other resins.
Although the return temperature to the dryer
may only be 140-150 F, there is a temperature
rise as the air passes through the blower and
another rise as it goes through the desiccant.
For these applications you’ll need to add,
typically, an extra post-dryer cooling coil in
the case of desiccant drying. This is also a
difficult thing for twin tower dryers to achieve.
They experience a spike in temperature each
time the towers switch as the partially cooled
regenerated bed comes on line. Another
option for these low temperature resins is the
membrane type dryer that can typically get to
low temperatures without the need for water.
They are limited to throughputs of about 200
lb./hr.
6
ake Precautions for
T
High Temperature Drying
When drying resins at temperatures in excess
of typically 220 F, there should be a post
hopper cooling coil with tower water. This
may also have a water saver valve to limit the
amount of cooling water used. Remember,
over-cooling (below 130 F) the air in the
cooling coil will require additional heating in
the process air heater and additional load on
the cooling water system.
7
eep Volatiles Out of Your Desiccant
K
Volatiles (organics) can come off of some
resins during the drying process. Resins such
as PET, nylons, PBT and some others can
give off significant amounts of these, over
time, and they can contaminate and destroy
desiccant. Even more, this contamination can
lead to carbon dust and that can enter the
drying hopper and contaminate the resin. All
systems subject to volatiles should have a
well maintained plasticizer system.
8
heck Moisture Level in the Resin
C
The moisture in the resin isn’t just a function
of the -40° dew point from the dryer. Best
practice is to use either an on-line or off-line
measurement tool to verify that the resin
leaving the drying hopper meets the process
requirements. Many products can have flaws
from under-dried resins and some, like nylon
and PBT, can become brittle if over-dried. The
only true way to know if you are sending
properly treated resins to the process is to
measure the resin moisture.
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 15
Haynie’s Dozen Drying Tips
9
Inspect Your Desiccant
The desiccant types that are typically used in
plastics industry dryers are Molecular Sieve
beads, Silica Gel beads and Pure Crystalline
Molecular Sieve. The molecular beads are
typically used in twin bed dryers and produce
-40°dew point drying air when functioning
properly. They have a base of about 30% clay
so they are not as efficient as the pure
crystalline desiccant and should be replaced
on 2-year intervals. You can check it in the
following ways – if it is discolored – replace it.
If you gather a handful and squeeze it, you
should feel it warming up quickly. If it does
not – replace it. Silica gel does not produce
-40°dew point air so it is typically used to
provide a blanket of desiccated air in the tops
of silos. Pure Crystalline Molecular sieve is
typically used in desiccant wheel dryers. It
produces consistent -40°dew point air for
several years.
12 Don’t Ignore Warnings
Most dryer controls provide some kind of
warning when something is going wrong in
the system. Some controls give very simple
warnings while others will tell the operator
exactly what is going wrong and even offer
instructions for a “fix”. In either case, the
warning is indicating that some correctional
action is necessary or greater consequences
are going to follow. Simply acknowledging the
warning and turning it off is not the correct
procedure.
Your Central Dryer Has Pending
Temperature and Lung Failure...
10 Install A Return Air Hopper Screen
As a minimum, there should be a
screen in the return air (at the hopper)
to insure that resin pellets don’t leave
the drying hopper.
Listening for
Abnormalities
Checking and
Imagine Having ESP for
What’s Happening Inside.
Listening for Abnormalities
11 Check for Leaks
Leaks anywhere in a closed loop
system are bad. Inspect the system
regularly to determine if you have any
CheckingFollowing these simple tips will help keep
Pressures
issues. Leaks generally allow ambient air, with
your production line running more smoothly, with
a high moisture level, to enter the “closed
fewer emergencies – and that increase productivity
loop”. Air leaks can lead to significantly high
and profits.
power bills when more moisture has to be
“boiled” off of the desiccant.
The heaters inside your central dryer or the hopper heater boxes ultimately fail.
Typically the only way you know is when the dryer finally doesn’t make temperature.
But with Novatec’s ESP Prophecy Sensorlytics, that’s a problem of the past.
This exclusive platform detects progressive heater failure before the
entire bank of heaters is shut down. Plus our sensors are also monitoring
and predicting future performance issues with the regenerative blower,
process blower and cassette wheel drive to warn you in advance so
you can avoid unscheduled shutdowns.
Only from Novatec.
Have Drying Issues? Contact the doctor:
www.novatec.com/dryers
Mark Haynie: [email protected] | 443-457-1152
www.ptonline.com/knowledgecenter/plastics-drying
16 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
© Copyright 2015 Novatec, Inc.
800-237-8379 | www.novatec.com
NPE2015 Wrap Up
DOWNSTREAM EXTRUSION
NEW SIEMENS TOUCHSCREEN CONTROL FOR UP-CUT SAWS
INCLUDES MANY FEATURES AT NO EXTRA CHARGE...
New Product Recap
Introduced at the show, but prototyped with major extrusion customers over the past two years,
Novatec’s new NS-6 up-cut Extrusion Saw features a standard 7” color touchscreen control with
built in features that others consider options. Along with the unrivaled servo drive inclusion, this
makes the new Novatec saw unparalleled in precision, ease of use and value.
SERVO UP-CUT EXTRUSION SAW
INTRODUCED AT NPE 2015
Hinged table for
easy access to
blade shroud and
internal area
Pressure and
speed control for
saw blade and
clamp motions
Following suit with their exclusive line of
all servo pullers and cutters for downstream
extrusion, Novatec introduced its NS-6 up-cut
Extrusion Saw with a capacity of 20” diameter X
6” cut capacity. As with other Novatec extrusion
products, the servo drive has been incorporated
as a standard feature and is not an optional extra
as with all other ordinary up-cut saws on the
market today.
The fully enclosed blade cavity rises above the
table with included guarding for operator safety.
A 3HP saw motor with variable speeds from 22753300 rpm is standard with a 20” diameter blade
and 24” table travel. The machine also comes
with a standard touch screen PLC control with a
full range of standard controller options that are
optional elsewhere.
Easy to Use Touchscreen Control
Home Screen–Access to
All Saw Functions
Access to QUICKOPS screen
Home Screen has quick access
to all saw functions including
the quick-ops screen, recipe
selection, user setup and batch
counter screens.
Opens RECIPE
SELECT screen
Access to SETUP
Opens the BATCH COUNTER screen
Quick Ops Screen–View RealTime Performance of Saw
SET LENGTH
to be cut
Quick Ops Screen gives the
operator or supervisor a quick visual
check on all vital saw functions
including length control, recipe
selection, piece/box count and
scrap/test controls.
Touch buttons to CUT
PRODUCT, STOP, CUT
SCRAP or TEST CUT
Select/edit recipe
Piece & Box Count
Recipe Select–Store and
Recall Up To 30 Recipes
Recipe Selection Screen allows
the operator to set parameters for
up to 30 recipes in the control
including product identification,
cut lengths, speed control, test/
scrap cuts and clamp control.
Upper chip collection tube
18 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
Rich Vester
[email protected]
913-912-2973
www.novatec.com/products/extrusion/saws/
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 19
All Servo. All PLC. All Touchscreen. Now UL Panels Too!
®
Precision Control & Ease of Use Should Not Be Optional...
New Servo
Up-Cut Saw
Servo Cutters
for On-Demand
or Continuous
Operation
Choice of Single and Dual Servo
Drive Puller Models Ranging from
2” Wide to 6” Wide Models
Downstream extrusion for this century. Standard Touchscreen Intuitive Control.
Standard Servo Precision Drives. Now, UL 508a Electrical Panels as well. Smart
machines that offer the very best in precision, control and value without compromise.
www.novatec.com/extrusion
Standard 5-Year Warranty | Made in the USA
800-237-8379 | www.novatec.com
© Copyright 2015 Novatec, Inc.
NPE2015 Wrap Up |
CONVEYING
Conveying Speed Can
Be Your Enemy
Put the Brakes on Resin
Conveying Speed to Minimize
System Maintenance
By Jim Zinski,
Novatec Inc.
Here’s how to manage pneumatic
conveying speeds to extend equipment
life and reduce material waste in
your plant.
rials can soften during conveying, smearing inside
the conveying tube surface. This causes buildup
that can contaminate other materials or lead
to streamers and angel hair that block material
flow. Other materials can break easily during
conveying, leading to excessive dust, plugged
filters, and waste.
Moving bulk plastics from storage to process
These issues may sound like polar opposites,
through pneumatic conveying tubes is common
but in reality, both are
in most processing
largely a function of
plants and has been for
conveying velocity. As
As material moves faster,
decades. But times and
material moves faster,
particles generate more heat,
materials are changing,
particles generate
friction, and impact force, all of
and what worked in
more heat, friction, and
the past isn’t always
which contribute significantly to
impact force, all of which
enough for reliable
attrition and wear issues.
contribute significantly to
results today.
attrition and wear issues.
One key issue
processors face is
VELOCITY EFFECTS ON
the problem of erosive wear of conveying tubing,
ELBOWS AND MATERIAL
bends, and other equipment subjected to abrasive
While it’s customary to use feet per minute
materials. Unexpected part failures can create
(fpm) when discussing air speed in a conveying
costly repairs and unplanned downtime. This is
system, this article uses miles per hour (mph) to
a growing problem due to expanded use of glass
more easily relate to everyday experience. For
and mineral fillers for improved part performance.
added context, we’ll consider two examples of
Another common problem is attrition, or
speed-related conveying issues.
degradation of sensitive raw materials. This is
often the byproduct of conveying heat-sensitive
materials like LDPE or dried acrylic. These mate-
22 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
The first issue is erosive wear
of elbows. Figure 1 illustrates how
conveying speed affects elbow life
when transferring abrasive materials.
As expected, higher speeds create
faster erosion, with a dramatic decrease
in relative service life from 35 to 45
mph. Continuing through the range of
expected conveying speeds, the actual
drop in service life is less dramatic, but
as a coarse rule of thumb, the relative
service life drops by about half for every
10 mph increase in air speed.
Understanding the impact of
velocity on conveying system
operation can greatly improve
your chances for success,
especially when moving
abrasive plastics and those
sensitive to degradation.
FIG 1
ELBOW SERVICE LIFE DECREASES AS
CONVEYING SPEED INCREASES
100%
(Based on material conveyed
before failure; 2-in. carbon
steel pipe transferring sand)
40%
19%
35 mph
6%
45mph
55 mph
65 mph
Conveying Air Speed
75 mph
Higher speeds create faster erosion, with a dramatic
decrease in relative service life from 35 to 45 mph. As a
coarse rule of thumb, the relative service life drops by
about half for every 10 mph increase in air speed.
FIG 2
LDPE STREAMER GENERATION GROWS
AS CONVEYING SPEED INCREASES
1.6 oz
(Oz/ton LDPE conveyed; 4-in. pipe,
8:1 solids loading; 122 F)
The second example of velocityrelated conveying issues results from
material degradation. Figure 2 illustrates how conveying speed affects
streamer generation when transferring
softer, heat-sensitive materials—LDPE
in this case. Once again, higher speeds
contribute to increased problems.
Streamer generation increased linearly
through the range of speeds, assuming
a consistent level of material loading in
the conveying line. Using 45 mph as a
baseline, streamer generation increased
an additional 55% for every 10 mph
increase in air speed.
Clearly slower is better to avoid these
problems. Unfortunately, there is more
happening inside a conveying system
than meets the eye.
9%
1.2 oz
0.9 oz
0.6 oz
45mph
55 mph
65 mph
Conveying Air Speed
75 mph
Here, streamer generation increased linearly through the
range of speeds, assuming a consistent level of material
loading in the conveying line. Using 45 mph as a baseline,
streamer generation increased an additional 55% for
every 10 mph increase in air speed.
QUESTIONS ABOUT RESIN CONVEYING?
Visit the CONVEYING KNOWLEDGE CENTER at
www.PTonline.com
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 23
Conveying Speed Can Be Your Enemy
AIR MOLECULES MOVING WITH/WITHOUT MATERIAL LOADING
Pump On (air only)
Lower vacuum = Less air expansion
(modest air-speed increase)
Vacuum = 0 Hg
Air Speed = 35 MPH
(target pickup speed)
Vacuum = 6 in. Hg
Air Speed = 44 MPH
Pump On (air and material)
Higher vacuum = More air expansion
(large air-speed increase)
Vacuum = 0 Hg
Air Speed= 35 MPH
(target pickup speed)
Vacuum= 12 in. Hg
Air Speed = 60 MPH
When air molecules move without material loading (top), less vacuum is needed, so the air is “stretched” less and accelerates to a
modestly higher speed. When material is added (bottom), every foot of tube, every change of direction through elbows, and every
pellet being carried create more resistance to air moving. This steadily growing resistance is overcome by increasing vacuum to keep
air and pellets moving. This elevated vacuum “stretches” the air even further, so the air moves much faster as it reaches the pump.
UNDERSTANDING VELOCITY IN A
VACUUM SYSTEM
Picture a drag race. The light tree turns green
and the dragster goes from zero to 30 in a heartbeat, then continues to accelerate faster and
faster down the track, throttle wide open to the
finish line.
Pellets in your conveying system are like a
dragster on the strip—starting from a standstill at
your source, then accelerating faster and faster all
the way to your receiver.
The vacuum pump is like the engine at full
throttle, pulling the material ever faster. And the
harder it pulls, the faster it moves everything down
the line toward it. The pump’s “pull” is the vacuum
it draws, measured in inches of mercury (in. Hg).
As vacuum increases, air is essentially
being “stretched” farther and farther apart, or
expanding, as it moves from the source toward the
pump. The top graphic in Fig. 3 above illustrates
air molecules moving without material loading.
Less vacuum is needed, so the air is “stretched”
24 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
less and accelerates to a modestly higher speed.
The bottom graphic in Fig. 3 adds material
loading. In this case, every foot of tube, every
change of direction through elbows, and every
pellet being carried create more resistance to
air moving. This steadily growing resistance is
overcome by increasing vacuum to keep air and
pellets moving. This elevated vacuum “stretches”
the air even further, so the air moves much faster
as it reaches the pump.
SPEED ZONES IN CONVEYING SYSTEMS
The area where material enters the conveying
line is often referred to as the pickup zone. For a
conveying system to work, air in this area has to
move fast enough to sweep the pellets into the
airstream from a standstill.
The acceptable speed range in the pickup zone
is approximately 35-45 mph. The required speed
varies depending on material properties such as
bulk density, particle size, and surface friction, but
for most plastic pellets, the minimum speed, or
pickup velocity, is around 35 mph.
Figure 4 shows how much air
FIG 4 AIR SPEED INCREASES FROM PICKUP TO PUMP
speed increases in a conveying
100 mph
system. When a pickup speed is
90 mph Pickup
chosen, the pump air speed is
Air speed at pump for 45
80 mph Zone
selected based on the expected
mph at pickup
70 mph (air in)
operating vacuum. A higher vacuum
60 mph
“stretches” air more, which requires
50 mph
higher air speeds downstream at the
Air speed at pump for 35
40 mph
mph at pickup
material receiver and at the pump.
30 mph
Air moves faster as it is stretched by vacuum →
Why is this important? As pellets
20 mph
024681012
14
gather speed moving through a
conveying system, they become
Pump Inlet Vacuum
projectiles hurtling toward impact
Higher vacuum leads to proportionally higher air speeds downstream and at the
targets like elbows and the receiver/
pump. A lower pickup speed keeps the downstream increase to a minimum.
separator. More speed equals more
problems, which are typically more
prevalent toward the destination
To reduce velocity, we might be tempted to
rather than the source. We want to target
choose a conveying tube size larger than needed
these areas for protection, and when possible,
to reduce vacuum. Less vacuum will “stretch” the
limit the downstream speed to minimize the
air less, and air speed will change less from start
damage it can cause.
to finish as a result. Unfortunately, most standard
pump packages already pull air at a preselected
speed. If it pulls less vacuum, the unintended
CONVENTIONAL DESIGN APPROACH
result is more speed at the pickup area. And since
Designers consider the conveying rate required
most standard pumps pull more air when faced
to keep up with processes, and the physical layout
with less target resistance, the maximum speed
of a given processing plant, to select the required
increases as well. More speed at all points in the
combination of tube size and pump to carry the
system leads to more problems with abrasive or
load. Higher vacuum yields higher conveying rates
sensitive materials.
and improved efficiency for a given tube size.
There are a variety of ways to reduce velocity
Larger tube sizes carry more material for a given
in a conveying system, some simpler than others,
vacuum level.
and some more versatile. We’ll consider several
Many standard pump packages on the market
methods, starting with the simplest:
have been selected to provide the maximum
rate for the selected tube size by delivering
• System-wide velocity reduction: A
the maximum safe vacuum level. This vacuum,
controlled air leak is one of the easiest ways
combined with the target pickup air speed,
to reduce velocity to all receiver stations in an
dictates the maximum air speed required downexisting vacuum-conveying system operating
stream at the pump.
above minimum pickup speed. An air leak
creates an alternate path for air to enter the
conveying line, like a simple bypass. It’s created
As pellets gather speed moving through
by adding a series of holes to the vacuum line
a conveying system, they become
before the pump safety filter. The size and
projectiles hurtling toward impact targets
number of holes, along with operating vacuum,
like elbows and the receiver/separator.
determine the magnitude of the air bypassing the
conveying system.
More speed equals more problems.
Air Speed
FIG 3
Continued on pg 28
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 25
Novatec IS Plastics Conveying & Systems
More Products. More Expertise. More Solutions.
• Certified team of conveying systems specialists
• Complete line of products for almost every application
• Turnkey design and installation availability
• Industry leader in client satisfaction and problem-solving results
Standard 5-Year Warranty | Made in the USA
800-237-8379 | www.novatec.com
© Copyright 2015 Novatec, Inc.
Conveying Speed Can Be Your Enemy
An air leak that’s carefully controlled can
reliably reduce system air speed by as much as
30%. But keep in mind that the air leak steals air
from the pickup area, so it can cause problems
if unplanned or poorly implemented. Symptoms
such as material slugging, or a complete line plug,
can result when the leak is large and the material
loading is high. It’s important to work with a
knowledgeable system designer to ensure
expected results.
Reducing the pump rpm also reduces air
speed across the system, with the added benefit
of modest energy savings. If the pump package is
belt driven, the sheave combination can often be
modified to slow the pump to a new target performance point. If the pump package is a direct-drive
setup, a variable-frequency drive (VFD) can be
used to select the new target performance point.
Once again, a knowledgeable system designer
having full application details and pump performance information should be consulted to ensure
safe operation and a successful outcome.
When overall air speed is reduced, the system
vacuum may need to be reduced to ensure
enough air speed at the pickup. This can be done
at the material source pickup probe by rotating
the collar to pull more air through the screen,
so less material enters the conveying line (see
photo, right).
A word of caution when operating at lower
vacuum levels, particularly less than 8 in. Hg
vacuum: In these situations, the limiting factor
can sometimes be the pump’s ability to get a fully
loaded conveying line moving from a complete
stop, which can exceed the vacuum needed to
carry the material once in motion. This is affected
a great deal by the system installation, particularly
how well the designer managed to avoid material
plug areas, such as the arrangement at the base of
a vertical tube, or consecutive 90° elbows.
• Controlling velocity variation: A central
conveying system often moves material from
a common source to multiple points of use.
To optimize operation, the material feed rate is
adjusted while transferring material to the receiver
station farthest from the material source. This is the
28 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
station that will encounter the most resistance, and
the feed rate is adjusted here to achieve the target
operating vacuum.
But when the same source feeds another
station located a shorter distance away, the
system resistance is reduced, and the vacuum
level at the pump decreases. Unfortunately, once
more, system air speed will increase when vacuum
load on the pump decreases, assuming the pump
rpm stays the same.
There are two basic methods to address this
common variation in air speed. One is mechanical,
and the other uses advanced system controls and
a VFD.
The simple mechanical approach is a flow-control valve, which acts like a governor on the air
speed inside a conveying system. When system
resistance drops (think short distance vs. long
distance), the flow-control valve adds the resis-
FIG 5
FLOW-CONTROL VALVE REGULATES AIR SPEED INSIDE A CONVEYING SYSTEM
When overall
air speed is reduced,
the system vacuum may need to be
reduced to ensure enough air speed at the pickup.
This can be done at the material source pickup probe by
rotating the collar to pull more air through the screen, so less
material enters the conveying line.
tance back into the system, so vacuum and air
speed remain steady in a targeted range. When
the system resistance is already high, and the
system air flow is near the design target, the
flow-control valve allows the air to pass through
unimpeded (see Fig. 5, p. 7)
The flow-control valve is also a good addition
to a system that purges the material line empty
during each conveying cycle. Purging is often
done when conveying dried or blended material
from a central location to preserve the material
dryness or blend integrity. In a purge system, the
resistance in the empty conveying line starts low,
then rises to a peak value as material fills the line.
When the purge cycle begins, the line gradually
A flow-control valve acts like a governor on the air speed inside a conveying system. When system resistance drops, the valve
adds the resistance back into the system, so vacuum and air speed remain steady in a targeted range. When the system
resistance is already high and the system air flow is near the design target, it allows the air to pass through unimpeded.
empties, and the resistance slowly drops to the
lower vacuum level. This natural variation in resistance and vacuum level is automatically corrected
by the flow-control valve to guarantee a predetermined maximum air speed for all stations.
• Selecting velocity by station: Advanced
conveying controls offer the ability to select a
conveying speed for individual stations. A pump
speed setting is stored with each station’s parameters, and this setting communicates to a VFD
installed with the pump. This flexibility allows the
operator to compensate for variations in setup,
such as lower rpm and airflow to convey shorter
distances and lighter line loads.
The ability to select conveying speed by
station adds versatility to handle specific materials
differently. General-purpose resins that are less
sensitive to velocity effects can be set to move at
default speeds to achieve maximum conveying
rate. Very heavy materials, or those having poor
flow characteristics, may be set to move at
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 29
Conveying Speed Can Be Your Enemy
NPE2015 Wrap Up |
elevated speeds. And, of course, stations can be
set to lower speeds to minimize material attrition
and erosive wear as needed.
These controls sometimes offer speed variation during a single conveying cycle. With this
capability, the pump can initially run at full speed
to reliably initiate material movement, and reduce
the possibility of line plugs or slugging at the start
of the conveying cycle. Once material is moving,
the pump rpm can be dropped to provide the
selected speed for the duration of the fill cycle.
Going one step further, if the material line is
purged, the pump rpm can be reduced as the
conveying line empties and resistance drops.
This reduces air flow as the vacuum decreases,
ensuring a maximum speed will
not be exceeded.
the large-diameter distance, speed decreases,
along with resistance to movement, so the pump
can carry more material. The key is understanding
how resistance builds in the conveying line and
how it affects the air speed throughout the entire
distance material travels.
Understanding the impact of velocity on
conveying system operation can greatly improve
your chances for success, especially when moving
abrasive plastics and those sensitive to degradation. Selecting the right system, and applying
advanced velocity-control methods, will protect
your investment, improve system uptime, and
reduce maintenance.
In addition to velocity management tools,
appropriate component options
should be considered to extend
maintenance intervals and the
An air leak that’s
• Velocity control in
overall life of the system. For
carefully controlled
long-distance conveying:
softer, heat-sensitive materials,
can reliably reduce
Conveying materials over longer
using surface-conditioned elbows
system air speed by
distances requires more vacuum
(shot-peened, spiral-grooved)
as much as 30%
to achieve a given transfer rate.
provides improved protection
When rate and distance require
against streamers and angel hair.
vacuum levels from 12 to 15 in. Hg,
For abrasive materials, glass
resulting air speeds are often faster than preferred
elbows and extended-wear options on receiver
for both abrasive materials and those sensitive to
stations can extend service life. There are also a
degradation.
number of specialty elbows available that enhance
But there is a way to achieve lower conveying
system operation and service life for both of these
speeds at high vacuum and improve your transsensitive material types.
fer-rate efficiency in the process. Velocity in
A conveying system is a sizeable investment
these systems can be reduced by implementing
that can impact a facility’s operations for years to
a dual-diameter conveying line, or stepping the
come. Ask your system designer to explain these
tube diameter to a larger size at a strategic point
options and their potential benefits before making
between the material source and the material
your decision.
destination.
To understand what happens, think of water
ABOUT THE AUTHOR:
flowing through rapids, then into a wider area
Jim Zinski is v.p., system design for Novatec Inc.,
of the stream. The same amount of water flows
Baltimore and has more than 25 years of experithrough each area, but it expands into the larger
ence in auxiliary equipment. His responsibilities
area and flows more slowly.
include strategic planning, product management,
In a conveying system, we can take advanand R&D for pneumatic conveying and central
tage of the reduced speed in the expanded line
control product lines, plus application oversight for
to increase the material transfer rate substantially
engineered systems. Contact: (443) 457-1379;
under higher vacuum—up to 50% or more added
[email protected]
rate versus traditional systems. By maximizing
30 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
CONVEYING
New Product Recap
BRUSHLESS LOADER GSL SERIES EXTENDED
TO INCLUDE BOTH 19 LB. & 12 LB. SIZES
Novatec’s popular GSL series brushless loaders which have only been available
in 19 lb. sizes for the last three years have now been augmented with the addition
of the GSL-12 which is a 12 lb. loader. As before, the GSL-12 will feature integrated
pendant control, brushless motor, a patented tilt feature for easy clean-out, and
a micro-burst patented high flow blowback valve and on-board compressed air
accumulator to keep the discharge clear and the filter clean. The included pendant
control includes a magnetic back for easy mounting on the machine—and has
timers, counters and alarms already installed.
COMPONENT WEAR WITH ABRASIVE MATERIAL IS
INEVITABLE, BUT EXTENDED LIFE IS POSSIBLE
THE PROBLEM
Abrasive/filled resins may add value and strength to end products,
but processors are at the mercy of these resins wreaking havoc on
their equipment. Accelerated wear of conveying tubing, bends and
other equipment can lead to unexpected part failures, vacuum leaks,
plugged lines, costly repairs and unplanned downtime.
THE NOVATEC SOLUTION
Extend the life of installed conveying equipment by choosing
Novatec wear-resistant components. Glass elbows can last up to 20x longer than traditional 16 gauge
stainless steel elbows. Replaceable, ceramic coated receiver parts such as inlet tubes, vacuum checkvalves and body wear plates improve service life and reduce future replacement costs. Reducing
conveying air and pellet speed extends life as well as conveying system velocity control methods such
as an air flow regulator, dual diameter convey lines and variable speed controls.
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 31
Conveying: New Product Recap
NPE2015 Wrap Up |
Detect When Equipment Needs
Maintenance—Before It’s Too Late
MANIFOLD SELECTION STATION–
REPLACE GUESS WORK WITH
PEACE OF MIND
Novatec’s QSM Quick Select Manifold, equipped
with Auto-ID Proofing of material sources to
machine mounted receivers prevents sending the
wrong material to your process, eliminating waste
and lost productivity. The QSM’s upright manifold
design delivers pellets to the target station more
reliably, and empties more quickly, than manifolds
mounted on an angle. The upright design also
means that when pellets bypass the intended branch, they are
captured in the manifold overshoot extension and quickly fall back
into the intended conveying air path. Auto ID is an efficient, less
expensive alternative to other material selection methods.
New technology to debut at NPE
warns when preventive maintenance is
needed, before equipment failure
disrupts production.
Enjoy the conveying benefits
of a positive displacement
(PD) vacuum pump without
the excessive noise. Novatec’s
exclusive Silencer Vacuum
Pumps operate less than 80 dbA
even at full load –with no enclosure required. Delivers strong,consistent PD vacuum and
airflow in a safe, lower noise,
working environment. Space Saving Design–almost 20% reduction in width versus standard VPDB series, and more than 40%
reduction in overall footprint versus PD with sound enclosure.
of sensor specialists Zreyes Technology, also
of Columbia. Prophecy offers patent pending
machine-mountable (using magnets or screws)
sensors made out of a single silicon chip, as well
as a patented wireless sensor network, a cloudbased distributed data-management system,
and analytics that monitor a variety of machine
signals to help predict incipient failure and alert
users when maintenance is needed or should be
scheduled.
Data can then be viewed
with app-equipped smart
devices. By monitoring
vibration data in real time,
a Prophecy app will track
abusive operation for
preventive maintenance so
that pumps can last longer.
NEW SVPD PUMP
REDUCES NOISE IN
YOUR PLANT
32 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
PROPHECY
On a “Prophecized” pump, machine-mounted sensors
(yellow) gather temperature and vibration data from the
blower on a real-time basis.
Is the “run-to-fail” era of operating plastics
processing machinery until it drops dead about
to come to an end? It will be if a startup company
specializing in “smart” predictive-maintenance
sensors and a cloud-connected mobile app has
its way.
NPE2015 next month in Orlando, Fla., will
mark the coming out of Prophecy Sensorlytics, a
Columbia, Md., company (prophecysensorlytics.
com) launched last year following the purchase
Data from these sensors is uploaded to a cloud
server or to the processor’s own intranet, where
trends can be viewed and analyzed from anywhere
in real time on smart devices equipped with the
mobile app, and over the internet via PC, etc.
“We have developed a complete and cost-effective platform to bring the new era of the
‘internet of things’ to mid-sized manufacturers,
which traditionally can’t afford expensive sensors
and sensor networks, for predicting machine
failures and getting the initial trend of a fatigued
machine to mobile apps,” explains Dr. Biplab
Pal, co-founder and chief technology officer of
Prophecy Sensorlytics.
“Most machines indicate pending failure in
the form of rising or falling surface temperature,
pressure, flow, vibration, sound, power factor, and
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 33
Detect When Equipment Needs Maintenance—
Before It’s Too Late
so forth. Our machine-‘wearable’ sensors can be
placed on old and new machines to track their
gradual failure so that a complete disruption of
production can be avoided by scheduled maintenance—knowing exactly where and when the
machine is going to fail or cause trouble.”
The technology is available through a licensing
arrangement. Prophecy’s first licensee is Novatec
Inc., Baltimore (novatec.com), which has exclusive rights to the technology on drying, conveying,
and downstream extrusion systems. At NPE,
Novatec will display what it is calling
“Prophecized” pumps used in materials conveying, and officials from Prophecy Sensorlytics
will be on hand in Novatec’s booth. “We feel once
we expose processors to this technology, they’ll
realize they can’t live without it,” states Conrad
Bessemer, Novatec’s president and CEO.
Novatec systems will include the predictive-maintenance technology at no extra cost,
Bessemer says. “Our objective in equipping
systems with this technology is to prevent
machinery breakdowns and failure,” he states.
“With open-source data and cloud-based
computing, it’s much less expensive to store and
access information for trending on what actually
is going on inside machinery. There’s nothing new
about sensors. But until now they’ve been expensive and ‘dumb’ from the standpoint that they
cannot communicate.
“There is also nothing new about ‘wearables,’”
Bessemer adds. “Consumers have for years been
wearing watches and other devices that monitor
their temperature, heart rate, and so forth. What
we’re doing is helping bring this technology into
an industrial environment where ‘run-to-fail’ is too
often the norm.”
HOW IT WORKS
In the system developed by Prophecy
Sensorlytics, data from these machine-mounted
devices is uploaded via a local wireless network
created by radio-frequency connected sensors.
Using proprietary software, this data is then
trended and analyzed to indicate if preventive
maintenance is needed.
The system will also send maintenance
alarms to personnel in the form of emails and text
messages. The data is visualized graphically, and
Prophecy app running on a tablet shows rising
temperature trend for a pump operating with old or
low oil. Real-time reporting is done against a baseline
for more visual understanding of deviation from
normal behavior.
Zone: 1
Machine: Motor
Process: All
Range: 6 months
Jul 14
Oil Overfilled
Aug 14
Low Oil Level
34 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
Sep 14
“Unfortunately, because such machines are
located in noisy and dusty industrial locations,
in most cases nobody acts on the alarm,” he
adds. “However, the system we developed tracks
temperature of airflow and the surface of the dryer,
which is extremely sensitive to changing filter
conditions of the blower. Even a slight change in
dirt condition in filter is detected with high and
repeatable precision, and its effect on drying is
captured in our mobile app visually.”
Motors on pumps and other devices are
tracked mostly from the vibration, rumbling noise,
and bad power factor they produce when the core
starts to fail due to abusive operation, low pump
oil level, etc. “All machines have a temperature,
vibrate, and emit sounds,” states Dr. Pal.
“Pumps are typically the core of any industrial
system. They have a pulse. They have a pressure.
They make sounds that can be analyzed. No
different than the human heart. In many plants,
signs that suggest maintenance is needed are
Once we expose processors to this technology at
no additional cost, they’ll realize they can’t live without it.
Motor Issues By Month
8
7
6
5
4
3
2
1
0
classified to identify a particular maintenance
problem so that personnel can quickly learn
about it; any data point shown in red, for example,
warrants immediate attention. By clicking on a red
alarm, more detailed analysis logs are available
on possible causes of the problem so that maintenance personnel don’t have to waste time figuring
out what’s wrong. Moreover, any new failure can
be logged in as fresh data, which helps the system
identify trends and patterns to enable it to continuously “learn” when a machine is properly functioning, and when it isn’t.
States Dr. Pal, “Supervised learning for predictive maintenance on our platform is extremely
sensitive to changing machine conditions triggered
by a bad motor, clogged filter and pipes, etc. Most
of it is delivered via a combination of machinelearning algorithms based on sound, vibration, and
temperature data from the machine.
“Today the most common way to alert plant
personnel of possible machine failure is through an
Oct 14
Clogged Filter
Nov 14
alarm system of sensors inserted inside the equipment,” adds Dr. Pal. “However, in most manufacturing plants, the alarms are visual and available
at machines usually located in noisy and dusty
environments. In some advanced systems, alarms
are transmitted via an industrial bus network and
are available from the internet or a mobile app, but
such systems are beyond the reach of the most of
mid-sized manufacturing operations due to high
cost of sensors and data-acquisition systems.
But even the most advanced system does not use
predictive analysis of data involving multi-sensors
and their historical behavior to predict and track
continuous machine failure.”
Nowadays, Dr. Pal notes that if a dryer filter
is clogged with a lot of dirt, a differential-pressure gauge will typically send a local alarm.
ignored until the pump fails.”
Dr. Pal continues: “Sound analysis of human
hearts can diagnose the 23 most common heart
diseases. That is well understood, and we have
learned from these studies. Machine sounds are
easier to analyze since machines of a particular
model will not show the level of variation that can
be found in a human heart.”
WIDE RANGE OF OTHER APPLICATIONS
While Novatec has exclusive rights to Prophecy on
its systems, the technology can be used on virtually any other type of equipment. On injection
molding machines, for example, it could be applied
not only to pumps, drives, and motors, it could
conceivably be deployed to ensure platen parallelism as well.
Dec 14
Abusive Operation
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 35
Detect When Equipment Needs Maintenance—
Before It’s Too Late
NPE2015 Wrap Up |
With extruders, Prophecy technology can, for
instance, be used on gearboxes to monitor oil
pressure and vibration, as well as motor temperature. “We are also looking at ways in the future
to use vibration to measure changes in screw/
barrel wear,” states Dr. Pal. “Ultimately Prophecy
Sensorlytics will look to work with extruder and
molding OEMs who have their own sense of
things to be monitored. Other markets that we are
working on in the future include motors and the
like for chillers, etc.”
States Dr. Pal, “The vision of Prophecy
Sensorlytics is to bring a ‘3P’ maintenance
mode to small- and mid-size manufacturers:
Equipment will be predictive in that it provides an
early warning before failure; preventive in that it
indicates when a machine is being abused; and
prescriptive in that it compares historical data
looking for solutions.”
Prophecy app running on a tablet shows rising
temperature trend for a pump operating with old or
low oil. Real-time reporting is done against a baseline
for more visual understanding of deviation from
normal behavior.
By Jim Callari, Editorial Director,
Plastics Technology magazine
Reprinted with the permission of Plastics
Technology magazine, Gardner Business Media.
36 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
DATE
ISSUE
1-Dec-14
3-Dec-14
10-Dec-14
14-Dec-14
20-Dec-14
23-Dec-14
3-Nov-14
5-Nov-14
10-Nov-14
20-Nov-14
23-Nov-14
24-Nov-14
4-Oct-14
6-Oct-14
12-Oct-14
21-Oct-14
27-Oct-14
4-Sep-14
6-Sep-14
12-Sep-14
14-Sep-14
27-Sep-14
4-Aug-14
6-Aug-14
12-Aug-14
21-Aug-14
27-Aug-14
1-Jul-14
3-Jul-14
10-Jul-14
14-Jul-14
20-Jul-14
Abusive Operation
Abusive Operation
Clogged Filter
Low Oil Level
Oil Overfilled
Low Oil Level
Oil Overfilled
Low Oil Level
Clogged Filter
Abusive Operation
Abusive Operation
Low Oil Level
Oil Overfilled
Low Oil Level
Clogged Filter
Abusive Operation
Abusive Operation
Oil Overfilled
Low Air Flow
Clogged Filter
Abusive Operation
Abusive Operation
Oil Overfilled
Low Air Flow
Clogged Filter
Abusive Operation
Abusive Operation
Abusive Operation
Abusive Operation
Clogged Filter
Low Air Flow
Oil Overfilled
23-Jul-14
Abusive Operation
30-Jul-14
Abusive Operation
Personnel can access historical records of
alarms on motors in real time on a mobile app
with Prophecy technology. Graph and table
above detail specific issues.
PROPHECY
Update on Predictive
Maintenance Sensorlytics
Novatec introduced several of their
machines at NPE 2015 featuring the
new Prophecy Sensorlytics Predictive
Maintenance Platform.
Without a doubt, it was one of the biggest hits
of the show as processors from all across the
plastics industry witnessed typical dashboard
demonstrations via a large interactive screen
presentation.
We’ve interviewed Dr. Biplab Pal, the Chief
Technology Officer and founder of Prophecy
as well as Conrad M. Bessemer, President of
Novatec, Inc. about the impressions from the show
and the next steps for this new development.
Mr. Bessemer: The reception was enthusiastic, however it was soon clear to us that
processors wanted a solution not just on their
new Novatec equipment, but also on existing
equipment in their plants. As a result, we’ve been
working with Dr. Pal and his team to develop some
retrofit sensor packages that can be applied not
only to existing Novatec pumps, but also other
competitive brands as well. (see inset on page 39)
EDITOR: Since The National Launch Of
Prophecy Was At NPE 2015 Within The
Novatec Booth, What Did You Learn From
Processors And About The Industry In
General?
Dr. Pal: The launch was a huge success. We
talked to thousands of processors and also many
other machinery manufacturers and demonstrated
the Prophecy dashboard platform as well as
discussed the infrastructure behind our solution.
The processors instantly understood the value
of the new platform and the improvement that it
could offer to avoiding unscheduled maintenance
in the facility. For example, on our product that
attaches to a new vacuum pump, we can see belt
variation and wear, oil viscosity changes, and high
and low oil levels. Since these pumps are normally
in isolated locations of the factory, this avoids the
problems associated with manpower trying to
measure the changes themselves.
EDITOR: So In The Few Months After The
Show What’s Been Going On With This
Exciting New Product?
Dr. Pal: Our first priority has been to
commence the user trials for the Novatec dryer
and pump customers so that we can fully
commercialize those products during late 2015.
Our team of over 20 developers has been working
on extensive tests and re-tests using Novatec
pumps and drying equipment as well as fine tuning
the app we previewed at the show. In addition,
we have filed over ten patents protecting our
intellectual property.
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 37
Update on Predictive Maintenance Sensorlytics
NPE2015 Wrap Up |
We expect to start incorporating the sensors
on all Novatec central dryers and large hoppers
shortly. This will detect process and regen blower
trending and predictive analytics in addition to
diagnosing which heater bank has the potential
to fail so that individual heater can be replaced in
advance of full failure.
Mr. Bessemer: The heater sensor should
be a great advance for the industry. Most heater
boxes have multiple legs and multiple heaters.
Individual heaters ultimately fail and then if multiple
heaters fail, the dryer fails to reach proper drying
temperature. In the past, the processor then
needed to diagnose which heater bank had a
problem resulting in long downtimes. Now with our
Sensorlytics platform we can detect which heater
bank has an individual failed heater so that the
processor can replace that heater in advance of full
heater bank failure. Until now, this has never been
available for central dryers in the plastics industry.
In addition to the dryer platform, we’ve been
working on a commercial introduction of the
sensor platform with Novatec pumps. As shown
at NPE, our platform will detect pump and blower
anomalies including oil viscosity, oil level, belt
vibration and more. We plan to start shipping
these in Q4 2015. These systems are especially
targeted to processors with multiple pumps in a
central conveying environment.
38 | NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW
PROPHECY
Prophecy to Release New Predictive Maintenance
Retrofit Products for Plastics Processors
EDITOR: So, What’s Next?
Dr. Pal: We plan to work in other industries
with requirements similar to Novatec. Many industries use industrial blowers for conveying material
including pharma, food and others. Novatec is a
great proving ground for us due to our joint-Maryland location, but the next step is offering similar
platforms to other industries outside of plastics.
In addition, as detailed in the sidebar on
inset 39, we are also developing some direct-toprocessor products. These direct to user sensorlytic products are a result of the processor input
at the NPE show. Processors told us that they
needed sensor platforms for existing equipment
so we’ve come up with some exciting products
that will be available to processors in early 2016.
Editor’s Note: Prophecy is the first machine
wearable predictive maintenance platform
that can detect machine problems over an
extended period of time. Using a unique
non-invasive sensor, the platform recognizes
oil viscosity changes, oil level changes,
heater variations, power factor, bearing
anomalies, and much more. For the full
article introducing Prophecy, please see
pages 33-36.
In addition to supplying ESP+ Predictive
Sensorlytics on new Novatec
central dryers and silencer vacuum
pumps, Prophecy has announced that
over the next 6 months, it will also be
introducing a series of products aimed
directly at plastics processors.
“This is a direct result of the thousands of
conversations we had with plastics processors at the National Plastics Exposition during
March 2015”, according to Dr Biplab Pal, Chief
Technology Officer of Prophecy. “Although
processors welcomed the announcement that
several new Novatec products would be equipped
with the predictive maintenance platform, they
also wanted predictive maintenance solutions for
existing equipment.”
Pal estimates that there are well over 30,000
vacuum pumps used in the plastics industry
primarily for resin conveying, but more importantly well over 500,000 vacuum pumps in general
industrial usage throughout North America. These
older pumps typically suffer from issues involving
rotor bearing or motor anomaly.
While the ESP+ version found on the Novatec
pumps offers a full pump predictive maintenance
system using the new machine baselines, the ESP
retrofit version will check more limited pump attributes including bearing anomaly, oil viscosity and
abusive operation. Further, because of the extensive baseline tracking on Novatec’s new vacuum
pumps, those users will also be able to check filter
condition, oil level and belt tension.
NEW LOW-COST CLOUD BASED
POWER QUALITY PLATFORM TO BE
COMMERCIALIZED IN 2016
With the widespread use of sensitive electronic equipment and machine controls, the
need for consistent power quality has accelerated dramatically. Dr. Pal commented, “Our
internal analysis has found that 80% of power
quality issues are due to internal, not external,
issues including improper wiring, overloading
circuits and varying internal loads due to
high initial draws. This power quality problem
significantly contributes to premature failure of
electronic equipment and motors, as well as
downtime on process lines. But the problem
is often intermittent and with current instrumentation costing thousands of dollars, the
solution often requires an experienced electrical
engineer to analyze the results. As a result,
many processors have just lived with the financial drain of power quality problems”.
Now as part of the development effort done
for the ESP+ Sensorlytics on Novatec’s central
dryers, Prophecy will be introducing a cloud
based power factor and power quality platform
that will enable processors to simply and inexpensively understand what’s going on with
power in their factory.
The new ESP Retrofit Sensors will be
available for select Beta customers in Q4 2015
and will be available for sale directly to users
Q1 2016. Processors interested in participating
in the select beta program should send emails to
[email protected]
NPE2015 WRAP-UP–THE SHOWS WITHIN A SHOW | 39
The Leader in Mobile Drying
Raises the Bar for Central Dryers...
Standard Rotating
Desiccant Wheel
Just Enter Your Polymer Type
and the Smart Control PLC
Does the Rest…
Standard UL508a
Electrical Panel
Standard Siemens
Touchscreen
PLC Control
Prewired for Prophecy
ESP Sensorlytics. Alerts
You to Pending Heater
Bank Downtime as Well
as Blower Performance.
Exclusive on Novatec.
Very Smart Upgraded
Software Senses Faults…
Standard Variable
Frequency Regen
Heater Drive. No
Extra Charge. Saves
Energy During Use.
Pictorially Guides
You in a Solution
Built-in Standards...
Sold as Options Everywhere Else!
www.novatec.com/dryers
Standard 5-Year Warranty | Made in the USA | 800-237-8379 | www.novatec.com
© Copyright 2015 Novatec, Inc.
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