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Upgrade adds 10-15 years of life to winders at Asia Pacific Fibers, Indonesia

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Case Study
Upgrade adds
10-15 years of life
to winders at
Asia Pacific Fibers,
Indonesia
PT Asia Pacific Fibers Tbk (APF) is...

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Challenges
A.T.E.’s automation team has handled many difficult
upgrades in the past. Hence, APF got in touch with
A.T.E. to...
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Upgrade adds 10-15 years of life to winders at Asia Pacific Fibers, Indonesia

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PT Asia Pacific Fibers Tbk (APF) is an Indonesia-based integrated manufacturer of polyester. They were facing a number of issues with a legacy winder such as poor windering quality, outdated communication protocols, unavailability of spares and hardware, etc. A.T.E. studied the machine and found that the machine was mechanically sound, but the electrical systems and controllers needed to be overhauled. After the upgrade, not only was the winder's life increased by 10-15 years, but monitoring was also easier, and spares were easily available at economical prices. Click on the link below to learn more.

PT Asia Pacific Fibers Tbk (APF) is an Indonesia-based integrated manufacturer of polyester. They were facing a number of issues with a legacy winder such as poor windering quality, outdated communication protocols, unavailability of spares and hardware, etc. A.T.E. studied the machine and found that the machine was mechanically sound, but the electrical systems and controllers needed to be overhauled. After the upgrade, not only was the winder's life increased by 10-15 years, but monitoring was also easier, and spares were easily available at economical prices. Click on the link below to learn more.

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Upgrade adds 10-15 years of life to winders at Asia Pacific Fibers, Indonesia

  1. 1. Case Study Upgrade adds 10-15 years of life to winders at Asia Pacific Fibers, Indonesia PT Asia Pacific Fibers Tbk (APF) is an Indonesia-based integrated manufacturer of polyester. The company has a manufacturing facility for PTA, continuous polymer and staple fibre in Karawang, Indonesia. It also owns another manufacturing plant for filament yarn in Semarang, Indonesia. CLIENT Asia Pacific Fibers Indonesia
  2. 2. Challenges A.T.E.’s automation team has handled many difficult upgrades in the past. Hence, APF got in touch with A.T.E. to see if the winder could be upgraded to improve its performance and to make it viable. § Limitation for product parameterization § Winding quality § DOS-based monitoring systems § High number of breakdowns and tripping § Special purpose drives manufactured only by OEM (original equipment manufacturer) § Short life of systems § Availability of spares and hardware § Expensive services from OEM § Lack of skilled manpower for maintenance § Limited or no production reporting APF has a winder of Barmag make. The control system hardware of this winder was obsolete. APF was also facing a number of other issues with the machine, such as: § Outdated communication protocols § Inventory management was costly Solution § Installed WINCC SCADA and HMI (human machine interface) systems with latest human machine interfaces § Replaced the existing OEM made hardware with the latest PLC (programmable logic controller) and computer system § The obsolete OEM-embedded controller was replaced with a S71200 PLC. § A.T.E. carried out a complete survey of the electrical hardware and related systems A.T.E. studied the machine and found that the machine was mechanically sound, but the electrical systems and controllers needed to be overhauled. § The DOS-based control station was replaced with the latest Siemens WINCC SCADA (supervisory control and data acquisition) § Installed the latest PROFINET communication protocol, thus making the machine future-ready § Replaced special purpose OEM drives with industry standard drives (such as Yaskawa and Siemens drives) which are easily available in market § All existing hardware replaced with the latest PLCs A.T.E. ENTERPRISES PRIVATE LIMITED T: +91-20-6717 0100 E: automation@ategroup.com W: www.ategroup.com CIN: U51503MH2001PTC132921 CS01 - V2, May 2021 Follow us on: § Machine life increased by 10-15 years § Spares are easily available at economical prices § Monitoring is easy as GUI is graphical and easy to understand § Parameterisation is made easy Results

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