GREENMILL 4.0
with Industry4.0 instruments
Packaging and storage facilities,
Gruppo Casillo, S.p.A.
GREENMILL 4.0
“The Industry 4.0 enabling technologies installed by Idea75 allowed us to significantly increase our mills production capacity and our energy efficiency through artificial intelligence.”
GREENMILL 4.0
“Idea75 helped us to reduce the energy consumption of plants and the production waste with Industry 4.0 technologies against the machinery and processes inefficiencies of our mills.”
GREENMILL 4.0
with Industry4.0 instruments
Packaging and storage facilities,
Gruppo Casillo, S.p.A.
GREENMILL 4.0
“The Industry 4.0 enabling technologies installed by Idea75 allowed us to significantly increase our mills production capacity and our energy efficiency through artificial intelligence.”
PROJECT DATA
Project coordinator: Idea75
Category: Industry 4.0
Location: Corato
Start:11/2018 – End: 04/2020
Cofunded by POR Puglia FESR-FSE 2014-2020
Asse prioritario 1 – Ricerca, sviluppo tecnologico, innovazione | Azione 1.6 “Interventi per il rafforzamento del sistema innovativo regionale e nazionale e incremento della collaborazione tra imprese e strutture di ricerca e il loro potenziamento” | BANDO INNONETWORK – Aiuti a sostegno alle Attività di R&S | 397.040,33€
PROJECT DATA
Project coordinator Idea75
Category: Industry 4.0
Location: Corato
Start:11/2018 – End: 04/2020
Cofunded by POR Puglia FESR-FSE 2014-2020
Asse prioritario 1 – Ricerca, sviluppo tecnologico, innovazione | Azione 1.6 “Interventi per il rafforzamento del sistema innovativo regionale e nazionale e incremento della collaborazione tra imprese e strutture di ricerca e il loro potenziamento” | BANDO INNONETWORK – Aiuti a sostegno alle Attività di R&S | 397.040,33€
RESULTS
Monitored plant
Productivity capacity
Energy consumption
OBJECTIVES
The goal of the project was to create a hardware/software system for the continuous improvement of energy efficiency and optimization of productive milling processes with Industry 4.0 instruments.
In particular, the system was implemented in the milling production plants (semolina and flour) of the Casillo Group, world leader in the sector and end user of the project.
OBJECTIVES
The goal of the project was to create a hardware/software system for the continuous improvement of energy efficiency and optimization of productive milling processes with Industry 4.0 instruments.
In particular, the system was implemented in the milling production plants (semolina and flour) of the Casillo Group, world leader in the sector and end user of the project.
SOLUTIONS
We developed a modular system for decision support and data analytics focused on productive milling processes with integrated specialized modules:
- GM-DC (Data Collector)
- GM-EO (Energy Optimization)
- GM-MQ (Maintenance Quality)
- GM-ADV (Advanced Data Visualization)
MORE IN DEPTH
GreenMill 4.0 aims to achieve:
- continuous energy efficiency through the reduction of energy consumption of milling plants;
- optimization of production processes by eliminating defects in real time (Zero-Defect Manufacturing);
- predictive maintenance program for the operators and realtime machine data visualization through augmented reality.
GreenMill 4,0. architecture
Augmented reality
GreenMill 4.0 includes the following integrated specialized modules:
GM-DataCollector (GM-DC)
It is the Industry 4.0 data collector, based on hardware embedded and installed on the plant: the ingested data are sent to the GM-EfficiencyOptimization and GM-MaintenanceQuality modules for following analysis and evaluations.
GM-EfficiencyOptimization (GM-EO)
The decision support software module analyzes and processes big data ingested (through GM-DataCollector) and collected from automation and production management systems to achieve continuous energy efficiency of the plant and to optimize production processes, thanks to the calculation of the optimal configurations of machines, the real time processing and provisioning of a decision support to operators.
GM-MaintenanceQuality (GM-MQ)
Hardware/software module developed on an embedded platform that analyzes and processes big data ingested (through GM-DataCollector) and collected from automation and production management systems to provide operators with a predictive maintenance program, to signal any incipient failures (avoiding plant stops) and to minimize production defects in real time (correcting the grain mixtures to obtain flours and semolina with characteristics supplied by specifications).
GM-AdvancedDataVisualization (GM-ADV)
The module performs the visualization of the reports processed by the GM-EfficiencyOptimization and GM-MaintenanceQuality modules on the data ingested by GM-DataCollector, in order to monitor the status of the plant, the machines and the production process directly on the plant. The operator can view information regarding the quality of the production in progress, reports of non-optimal configurations of machines and processes or the state of health of the machine.
Visualization of hotspot on the P&ID with AR and pie menu to access machine information.
MonitorApp application screenshot.
PUBLICATIONS, ARTICLES, AWARDS
S.Grassi, A. Marti, D. Cascella, S. Casalino, G.L. Cascella
Electric Drive Supervisor for Milling Process 4.0
Automation: A Process Analytical Approach with
IIoT NIR Devices for Common WheatSensors 2020, 20(4), 1147;
The milling industry envisions solutions to become fully compatible with the industry 4.0 technology where sensors interconnect devices, machines and processes. In this contest, the work presents an integrated solution merging a deeper understanding and control of the process due to real-time data collection by MicroNIR sensors (VIAVI, Santa Rosa, CA)…
STAKEHOLDERS & CREDITS
MSc with honors & PhD in Electrical Eng.
Politecnico di Bari (IT)
EU Marie Curie Fellow
Nottingham University (UK)
40+ international papers
30+ industrial and R&D projects
GEM ICT Research and Development is an innovative SME of Sistematica Group specialized in the study, design and implementation of soft-computing algorithms and embedded platforms.
www.gem-ict.it
Tera is a young innovative SME based on the experience acquired over several years of activity by a group of engineers and managers operating in the renewable energy and electronics sector, both in industrial and R&D contexts.
www.terasrl.it
Politecnico di Bari is a public university with the aim of cultural, scientific and technological progress through research organization in science and technology of Architecture and Engineering fields.
www.poliba.it
