Introducing Quadrant Plastic Composites

Headquartered in Lenzburg, Quadrant Plastic Composites is considered a leading global manufacturer of glass mat reinforced thermoplastics (GMT, GMTex). Using raw materials such as glass fiber and polypropylene, along with other additives, the globally active company produces patented high-performance composite materials based on its own formulations. The main customer is the automotive industry, but these innovative materials are increasingly being used in the construction and capital goods industries as well.

Modernization of the Double Belt Press Control System

On the production machine, a massive double belt press, the composites are manufactured as a continuous “glass mat/plastic resin sandwich.” After the pressing process, the belt is cut into customized sheets and delivered as semi-finished products. Support and maintenance for the old Siemens control system could no longer be guaranteed. The risk of a sudden and prolonged plant shutdown was becoming increasingly high. Since this is a business-critical system, the decision was made to undertake a comprehensive modernization of the control system.

The Concept

The Simatic S5 was replaced by a modern Simatic S7-400 and a new plant visualization system (touch panel). A particular challenge was integrating critical control processes, which had been implemented at the time using third-party S5 cards, into the new S7 PLC program. These processes were previously tested in parallel operation to ensure the shortest possible production interruption during the actual conversion to the new control system. This parallel operation, which allowed for switching back to the old control system at any time, contributed significantly to the subsequent fast, smooth, and therefore cost-effective conversion and subsequent commissioning.

Customer Benefits

Thanks to the modernization of the control system, production can now be carried out efficiently, safely, and with better availability. This allows precise production schedules to be realized without downtime. This increases customer satisfaction and spares employees from having to work additional shifts.