TURCK - Smart moulds (GB)

Smart moulds – intelligente Formen
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Positioning Factory Automation
Enterprise
Layer
SOLVE IT!
Control
Layer
I/O-Layer
Connectivity
Layer
Sensor
Layer
2
BUS IT!
CONNECT IT!
SENSE IT!
Smart moulds –
intelligente
Formen
What is an intelligent chocolate mould?
•  Data can be written into the mould and read out again
•  The environmental conditions don’t influence the data storage and
exchange
•  They meet all the requirements that are demanded from conventional
moulds
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Smart moulds –
intelligente
Formen
What are the components of a RFID-aystem?
Field bus (e.g. Profibus, DeviceNet, Profinet, Ethernet, etc)
Interface IP67
Read-WriteHead
Data carrier
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contact-free
information
exchange
Smart moulds –
intelligente
Formen
Identification of chocolate moulds
•  Data carrier TW-R16-…
•  compact form factor
•  chemically resistant
•  vibration and temperature
resistant
•  food conform material according
to FDA
•  passive function without battery
according to ISO 15693
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Smart moulds –
intelligente
Formen
Identification of chocolate moulds
•  Read-write heads in M30 threaded
barrel housing
•  mould identification during production
•  wash-down version
•  high quality materials
•  high chemical resistance
•  food contact materials (FDA)
•  protection class IP69K
•  Read-write heads in Q80L400 housing
•  mould identification at the washing
machine
•  reliable identification of moulds
in different sizes
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Smart moulds –
intelligente
Formen
Which data are stored where?
ERP
write and
read
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number of cleaning cycles
number of production cycles
produced amount [kg/mould]
life span of the mould [days]
article number
product name
number of mould
date of production
depositing program
cleaning program
225
1400
1344
655
Agathon 11111/0
100g bar
267/1000
07.2007
Solid 100g
Hildebrand 4
Smart moulds –
intelligente
Formen
Which data are stored where?
Proposal of the working group
all data
ERP
data base
write once
read
repeatedly
number of cleaning cycles
number of production cycles
produced amount [kg/mould]
life span of the mould [days]
article number
product name
number of mould
date of production
depositing program
cleaning program
225
1400
1344
655
Agathon 11111/0
100g bar
267/1000
07.2007
Solid 100g
Hildebrand 4
unchangeable data
8
Smart moulds –
intelligente
Formen
RFID in chocolate production
Insertion into the production line
Depositing of chocolate
Detecting residues of chocolate
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Smart moulds –
intelligente
Formen
RFID in mould cleaning
Insertion into the washing machine
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Identification of the mould
Smart moulds –
intelligente
Formen
RFID in mould logistics
•  Standard mould containers
•  effective mould logistics
•  suitable for high-bay warehouses
•  RFID at the mould container
•  simplified storage and retrieval
•  complete transparency by linking the
data of the mould container with the data
of individual moulds
•  store location and mould data in the ERP
system
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additional data
carrier on the mould
container
Smart moulds –
intelligente
Formen
RFID in mould logistics
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Identification of mould containers
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Control of internal logistics
Smart moulds –
intelligente
Formen
Benefits for chocolate production
•  More flexibility and efficiency
•  automatic selection of the production program
•  the mould controls the processes
•  dosing
•  demoulding intensity
•  less down time
•  goal: mono-line performance for flexible lines
•  better documentation of the shift efficiency
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Smart moulds –
intelligente
Formen
Benefits for chocolate production
•  Better control of product quality and product safety
•  identification of the mold before the depositing process
•  compatibility check
•  identification and tracking of falsely or incompletely filled moulds
•  removal of moulds with repeated production problems
•  control of hygienic standards for each mould
•  tracking and removal of damaged moulds
•  acquisition and processing of mould related process data
•  Improved traceability
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Smart moulds –
intelligente
Formen
Benefits for mold cleaning
•  More flexibility and efficiency
•  optimal use of cleaning agents, water and energy
•  higher life span of moulds by reduction of the use of detergents
•  better documentation of the shift efficiency
•  Better control of product quality and product safety
•  avoid cleaning residues on the mould
•  prevent loss of mould gloss because of surface abrasion
•  reduced risk of mold fracture
•  Improved traceability
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Smart moulds –
intelligente
Formen
Benefits for mould storage
•  Mould management
•  pre-calculation of the expected mould life span
•  mould selection before a fracture occurs
•  permanent inventory of the stock of moulds
•  Save the mould data on the mould container
•  determine the storage location of moulds
•  pre-condition for a fully automated production of chocolate
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Smart moulds –
intelligente
Formen
Outlook
•  Combination of RFID with sensor functions
•  Acquisition of additional mould properties and link with the mould
database
•  …
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Smart moulds –
intelligente
Formen
Thank you for your attention!
Dr. Bernhard Grimm
Diplom-Physcist
Vertical Sales Manager Food and
Packaging Industry
phone: 0208 4952-148
e-mail: bernhard.grimm@turck.com
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Smart moulds –
intelligente
Formen