¿Tienes que poner al día un mezclador? Aquí encontrarás las respuestas a las preguntas más frecuentes

Necesitas actualizar tu mezclador y estás lleno de dudas. Lo cual es comprensible, porque se trata de una operación delicada que requiere días de inactividad, con todas las consecuencias del caso.

Para ayudarte a tomar las decisiones correctas, he compilado mi propia lista de preguntas frecuentes, nacida de años y años de experiencia.

Puede imaginarte las docenas de preguntas que, durante todo este tiempo, he tenido que responder; las legítimas dudas de quienes tienen que decidir qué hacer y quieren estar seguros de que están tomando la mejor decisión para su empresa.

A continuación hablo de las principales, las más frecuentes. Espero que también te ayuden a aclarar dudas, perplejidades, miedos (si tiene alguno).

 

¿ES MEJOR ESPERAR UNOS AÑOS Y CAMBIAR EL MEZCLADOR O MEJORAR YA LA AUTOMATIZACIÓN DEL EXISTENTE?

Eso depende.

Esta es una pregunta para la que no hay una sola respuesta que funcione siempre. La elección depende esencialmente de los siguientes factores:

  • si puedes financiar una inversión de varios cientos de miles de euros
  • si tus clientes actuales y los que puedan venir con la nueva máquina te permitirán devolver la inversión en unos pocos años.
  • si tu mezclador actual está al final de su vida o bien mantenido puedes usarlo durante varios años más.

Si puedes apoyar la inversión y si crees que puedes devolverla en un plazo medio corto (tiene que evaluar el retorno de la inversión), la compra de una nueva máquina te garantiza una producción de alta calidad durante varios años.

Pero si la máquina actual sigue en buenas condiciones y sólo necesita un buen mantenimiento mecánico, la actualización de la automatización (y tal vez la instalación de un variador de frecuencia si la máquina no está equipada con uno) te garantiza varios años de producción, teniendo todos los controles y funciones de los nuevos mezcladores pero invirtiendo menos de una décima parte del coste de una máquina nueva.

Si, por otro lado, la mecánica ha llegado al final de su vida, también puedes considerar un mezclador reconstruido (recomiendo reconstruido bien, no simplemente pintado) equipado con un moderno software de control. El coste es aproximadamente la mitad de una máquina nueva.

TENGO UNA VIEJA MÁQUINA QUE TODAVÍA FUNCIONA BIEN, PERO NO TIENE PLC, ¿PUEDES HACER ALGO AL RESPECTO?

Nuestra plataforma de software ha sido creada para adaptarse a todas las máquinas del mercado, incluso a las más antiguas.

En caso de que la máquina sea completamente electromecánica o incluso con controles neumáticos, por lo tanto no equipada inicialmente con un PLC, nuestros técnicos instalarán un moderno autómata.

Para ello, dependiendo del modelo del mezclador, se suministra una pequeña caja con un PLC ya cableado y equipado con todas las entradas y salidas necesarias. Analizando el cuadro eléctrico existente y la documentación actual (aunque sea muy antigua), se crean algunas conexiones para poder hacer con el PLC lo que ahora hacen los relés.

Podemos hacerlo porque sabemos exactamente cómo funciona la máquina y tenemos una gran experiencia incluso en máquinas muy antiguas.

SÓLO TENGO UN MEZCLADOR QUE NO PUEDO MANTENER PARADO. ¿CUÁNTO TIEMPO SE TARDA EN INSTALAR EL SISTEMA?

Una vez que hayamos completado el estudio sobre el mezclador existente y la documentación, podemos garantizar los días para hacer la actualización.

Hay tres discriminantes que afectan la rapidez del trabajo:

  • si la máquina ya tiene un PLC (aunque sea antiguo y limitado) que controla los movimientos;
  • si quieres hacer mejoras, por ejemplo instalando un variador;
  • si la documentación electromecánica de la máquina actual está presente.

A modo de indicación aproximada, puedes consultar esta tabla:

El mezclador ya está equipado con PLC y velocidad variable 2 días completos de paro

2 días para pruebas de producción limitada

Mezclador ya equipado con PLC pero sin velocidad variable (que quieres añadir) 4 días completos de paro

2 días para pruebas de producción limitada

El mezclador no está equipado con PLC o velocidad variable 5 días de detención completa

3 días para pruebas de producción limitada

Podemos garantizar estos tiempos de instalación con exactitud porque hemos realizado varias docenas de intervenciones en varias máquinas y porque todos los componentes de software ya están probados y listos para funcionar.

El tiempo más largo que suele tardar es comprobar que la máquina responde a nuestras órdenes (que los sensores funcionan, que el pistón se mueve correctamente, etc.).

MIS TRABAJADORES ESTÁN ACOSTUMBRADOS A TRABAJAR A MANO Y NO ESTÁN FAMILIARIZADOS CON LOS ORDENADORES. ¿CÓMO SE ENCONTRARÁN?

La interfaz de usuario del programa informático se desarrolló sobre la base de sugerencias e informes de docenas de operadores del mezclador. Por esta razón, es muy intuitiva y simple, pero al mismo tiempo asegura un control completo de la máquina.

Esta es la pantalla que tendrá el operador del mezclador:

stato mescolatore chiusoLa página es muy simple pero muestra rápidamente todos los datos y parámetros del mezclador.

Una vez que se acostumbren a utilizarlo y se perfeccionen las recetas de mezcla, difícilmente querrán volver atrás y la empresa habrá ganado en repetibilidad y trazabilidad de la producción.

Si quieres ver una demostración del programa, visita esta dirección.

HACEMOS PEQUEÑAS PRODUCCIONES Y CAMBIAMOS LA FÓRMULA CADA 2-3 CICLOS. ¿ESTÁ BIEN PARA NOSOTROS TAMBIÉN?

Si te encuentras en un sector especializado y cambias a menudo de fórmula, un software de control puede ayudarte porque si ahora trabajas en modo manual y el operador necesita conocer cada una de las fórmulas y recordar cómo manejarla puede cometer errores que sólo notarás al final del proceso en el laboratorio.

A través del monitor de nuestro programa se ayuda al operador a no cometer errores, sólo tiene que seguir las instrucciones para saber qué componentes cargar. Además, un lector de códigos de barras comprueba que los componentes son los establecidos en la producción.

Todas las demás operaciones en la puerta de carga, el pistón y los controles de tiempo, temperatura y energía son administrados automáticamente por el programa.

El enfriamiento de la cámara y los rotores también es controlado por nuestro programa (si la máquina está equipada con estos dispositivos), evitando los problemas de sobrecalentamiento del compuesto cuando se pasa de una mezcla de alto Shore a una de bajo valor.

Esto garantiza una mayor repetibilidad, menos errores y, por lo tanto, menos desperdicio (con evidentes ventajas económicas).

TODO BONITO, PERO ¿CUÁNTO VALE? AHORA NO ES EL MOMENTO DE INVERTIR

Siempre habrá amenazas en el mercado que te harán decir que no es el momento de invertir, pero siempre habrá grandes oportunidades para aquellos que puedan aprovecharlas.

Un buen empresario no debe invertir nunca un euro más de lo necesario, pero tampoco un euro menos de lo necesario.

La actualización de la automatización del mezclador, que es el elemento clave para producir mezclas de calidad, te permitirá tener una gestión real de los tiempos y los costes de producción (energía y personal); tener producciones más repetitivas; y no depender más del operador de la mezcladora.

Además, gracias a la trazabilidad y a los informes, puedes mostrar a tus clientes la calidad de tu producción y convencer incluso al técnico más escéptico.

No es posible dar una indicación unívoca del coste, hay muchos factores a tener en cuenta: desde el estado de la máquina hasta las opciones de accesorios que se quieran instalar (comprobar las cintas, leer los códigos de barras de la materia prima, añadir un inversor, etc.).

Para evaluar un primer nivel de inversión, la instalación de nuestro sistema completo en un mezclador ya equipado con PLC (aunque sea viejo y deba ser reemplazado) comienza a partir de 30.000 euros llave en mano e incluye:

  • un PC industrial para ver el estado de la máquina;
  • un PLC Siemens S7-1500 último modelo;
  • nuestro módulo de software para PC y PLC;
  • las actividades para reemplazar el viejo PLC y las pruebas.

¿No has encontrado la respuesta que buscas? Haz tu pregunta en un comentario en el post. Si deseas un consejo más específico, envía un correo electrónico a: claudio.tosi@multidata.it.

Buona vita

Claudio Tosi

Nato nel 1974 a Modena, si è diplomato all'istituto superiore Enrico Fermi in elettronica e telecomunicazioni. Dopo l'anno di militare ha iniziato il suo percorso professionale come tecnico programmatore presso la Multi Data s.r.l. Dopo oltre 20 anni di lavoro, si occupa di seguire i nostri clienti nel settore plastica e gomma, aiutandoli a migliorare la produzione e ridurre errori e costi.

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