Schulman identified that although their twin- screw extruder was, in hardware terms, relatively new (built 10 tears ago), the control system was rapidly becoming outdated. The original control system did not offer the reliability, performance and features necessary to operate in todays competitive marketplace within the Masterbatch industry.

(Naturally capacity and performance of all PC’s and plcs have improved exponentially since this line was originally conceived – the world has progressed from computers with MS-DOS through to the world today with PC’s with ever increasing speed and huge memory capacity plus of course, the Internet)
The first Schulman complete extrusion line project which we finished last year, was to replace an old instrument based panel on a Farrel compounding system producing (4) tonnes per hour of masterbatch. As soon as that control system was in place the feedback from ALL of the line operators was extremely positive.

They really appreciated the ease of operation and the logical interface, which was provided by a single Siemens operator panel (HMI) controlling every single aspect of the complete line from extruder heating zones, through to screen changer and underwater pelletizer. Schulman were keen to replicate the success of the BSG ONE operator interface and decided to install a complete extruder control system for one of their twin screw extruders. This control system was retrofitted onto the twin screw extruder on schedule within the two week summer shutdown. BSG Engineers provided installation and commissioning support, with all functions being tested and I/O check (Inputs and Outputs) completed before the complete new operator control was handed over to the production team.

More details and video online of this CASE STUDY at

The new BSG One Control features the latest SIEMENS S7 plc hardware which offers a range of benefits including faster data processing, support for Open communications via Profibus, and built in 24 hour remote assistance support from BSG CONTROLS via modem link.