How to secure your line availability
There are many reasons for line downtimes in plastics extrusion: broken components, faults in the control unit or power failures and supply bottlenecks. If the line is down, the loss of yield quickly adds up to a four-digit amount - and that per hour. Downtimes can never be completely avoided, but producers can prevent unplanned line stoppages. Reifenhäuser offers its customers not only reliable lines and components, but also several other options:
1. Repair and maintenance
The better a line is operated and maintained, the higher is the line availability. Reifenhäuser supports customers in this respect with various services, such as inspections and maintenance services, cleaning packages, the reworking of coextrusion adapters and dies, or the reconditioning of the entire production line.
With the help of digital solutions from Reifenhäuser's corporate startup RE:, customers can also find the optimal time for maintenance. Data makes transparent what is happening in production and also helps, for example, to identify patterns for faults in order to avoid line downtimes.
2. Stocking spare parts
Even with the best care of the equipment, wear can only be delayed, but not prevented. For critical parts and those that wear out more frequently - for example, screens, cylinders, and heating jackets - stocking spare parts in advance is one way to avoid idle times. Reifenhäuser offers customers various spare parts packages, adapted to the requirements of the relevant line. For customers who only reorder spare parts when needed, Reifenhäuser also stocks more than 25,000 different original spare parts worldwide.
Spare parts packages from Reifenhäuser
Customers who stock spare parts also take precautions against the discontinuation of parts due to their age. This is because extrusion lines generally have service lives of several decades. During this time, electronic components in particular continue to develop rapidly. At some point, many components are no longer state of the art or no longer available. If a small control unit is then defective, in the worst case, this stops the entire production. Reifenhäuser is therefore in close contact with suppliers and informs the customers concerned about discontinued components. They can then stock the corresponding component in advance.
3. Renew plants and components proactively
Spare parts packages are particularly recommended for lines that are up to ten years old. For older lines, certain spare parts may no longer be available. In this case, a rebuild of the line can ensure line availability. Discontinued components, such as drive units, are replaced by Reifenhäuser Service with a new version - including integration into the line control system. For older lines, a general overhaul of the line control system is also an option.
From old to new: Conversion of a line control system
The Reifenhäuser service team then converts all programmable logic controllers (PLCs) and frequency converters as well as all operating panels for extruder, haul-off and winder to a new version. This means that old lines are well positioned for many more years and the operation is comparable to new lines. Machine operators then do not have to master two systems - which in turn reduces operating errors and contributes to smooth production.
Customer stories: Line conversion
An extrusion line is a long-term investment. Read here how three film producers have made their lines fit for the future with modernization packages from Reifenhäuser.
You would like to increase your line availability? Then please feel free to contact us.
More News & Stories
