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OPTIMA CONVERTING TULLIS RUSSELL'S COATING PERFORMANCE

27 January 2011

A world leader in paper making, coating and converting reaped the benefits of turning a vital cog in its manufacturing assets into a record-breaker following a drives and control upgrade undertaken by Optima Control Solutions Ltd.

Drives, PLCs and SCADA systems are fundamental to keeping the wheels of the manufacturing industry turning and companies naturally rely on their machine control systems for production efficiency. Tullis Russell Ltd turned to Optima's expertise in this field to improve the operation of its Truflo Coater.

Tullis Russell had already worked closely with Optima on several previous projects and knew it could rely on the Blackburn-based company's record of successfully integrating their control systems.

The enterprising Scottish company, renowned for being at the forefront of coated paper and film development, enlisted Optima's help again to improve the performance of its Truflo coating operation which produces both high gloss and matt coatings to single and double sided paper.

Optima designed, supplied, installed and commissioned the complete control system retrofit of a Siemens S7-400 PLC and WinCC SCADA package with Parker SSD, DC and AC drives, all installed at times scheduled to coincide with the customer's planned downtime.

The result was another boost in production for Tullis, with the coater manufacturing a record amount of high-quality gloss and matt coated paper following the upgrade.

This project followed an earlier collaboration between the two companies when Tullis decided to replace the original analogue components on a Jagenberg Vari-Dur 120 Slitter-Rewinder with new digital technologies.

Optima transformed the Jagenberg's performance by installing a Siemens PLC and HMI, Parker SSD drives, ABB tension control, Pilz safety equipment and Sick optics, helping Tullis post a five percent improvement in its OEE and an associated 25 percent increase in productivity.

Optima's joint managing director Michael Hill said: "We have a lot of experience in designing drive systems for printing, coating and converting machines on a variety of substrates. Our engineers are passionate about what they do and we have a very good relationship with Tullis thanks to our understanding of the client's needs and our ability to design and integrate bespoke solutions."

Blackburn-based Optima Control Solutions has an unrivalled reputation for designing, building and commissioning high-quality drive control systems. Established in 1995, the company has grown steadily since then to provide a blue chip service to an impressive client base both here in the UK and overseas, including customers in Europe, China and South Africa.

For further information, please contact:

Michael Hill, Managing director
Optima Control Solutions Ltd
Capricorn Park
Blakewater Road
Blackburn
BB1 5QR
Tel: 01254 272829
Fax: 01254 272828
Email: michael.hill@optimacs.comWeb: www.optimacs.com
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