NIM
production plant
NIM
“Idea75 proved to be a reliable partner focused on achieving the set objectives. This determination led us to want to involve them in various industrial initiatives.”
NIM
“The coordination of NIM by Idea75 was managed in a methodical and punctual way, thanks to their ability to manage the technical, organizational and regulatory complexities dictated by the location of the plant in the USA.”
NIM
NIM
“Idea75 proved to be a reliable partner focused on achieving the set objectives. This determination led us to want to involve them in various industrial initiatives.”
NIM
“The coordination of NIM by Idea75 was managed in a methodical and punctual way, thanks to their ability to manage the technical, organizational and regulatory complexities dictated by the location of the plant in the USA.”
PROJECT DATA
Customer: New Wind s.r.l.
Category: Industry 4.0
Location: Los Angeles (California)
Start: 07/2018 – End: 10/2019
PROJECT DATA
Customer: New Wind s.r.l.
Category: Industry 4.0
Location: Los Angeles (California)
Start: 07/2018 – End: 10/2019
RESULTS
Fully automated and “Zero-defect” production plant
Increase of production capacity
Reduction
of energy consumption
Reduction of production
cycle time
Waste
OBJECTIVES
SOLUTIONS
The equipment is completely segregated and automated with interconnected components that can be managed remotely by the operator, whose sole responsibility is to select the desired recipe and program the quantities of the production batch.
The equipment consists of a foaming machine in which the raw materials are mixed, four automatic molds of adjustable dimensions, laid in battery for a length of about 20 m, that have arms for the automatic extrusion of the blocks, a transport system of the blocks, a weight system and a printer that marks the production parameters and two cartesian robots, one to position the foaming head and the other to automatically clean the molds.
MORE IN DEPTH
PLANT
NIM is a completely segregated and automated equipment, with interconnected components that can be managed remotely by the operator, whose sole responsibility is to select the desired recipe and program the quantities of the production batch.
This solution complies with the US standards UL 508A, Nfpa 79, SAE-ISO-EN-DIN, Ansi B-11.
FEATURES
The system consists of:
- a foaming machine in which the raw materials are conditioned and mixed;
- a color control unit;
- four automatic molds of adjustable dimensions, laid in battery for a length of about 20 m;
- a machine for the automatic extrusion of polyurethane blocks;
- a transport system of the blocks;
- a printer and a weight system, according to the production specifications, complete with an anti-adhesive application system for the subsequent stacking of the blocks.
OPERATION
The foam reacts inside the molds after the polyurethane dispensing through a distributor moved by a cartesian robot along two X-Y axes. The two X-Y axes, which represents the dispenser shuttle, move in the mold area (about 3×2 m).
A second cartesian robot applies preliminarily the release agent on the molds, so on board of the same gantry there is another shuttle, moved along an X axis of the gantry, with on board other two Y and Z axes for the release agent distribution.
The automatic molds are designed to satisfy the production of the required block sizes and they close ensuring the seal up to a pressure of 2.5 bar, developed by the reaction of the polyurethane. There is also a heat exchanger integrated in the molds: it is able to correct the evolution of chemical reactions and process parameters, depending on the environmental variables detected inside the production site, mainly temperature and humidity.
The equipment is designed to realize a parallel and differentiated production on the four lines associated with the molds and to recognize the possible removal of the molds for maintenance purposes.
Compared to similar equipment with standard technology, NIM achieved the following results:
- an increase in plant production capacity equal to +32%;
- the 13% reduction in global energy consumption of the production line;
- a production Cycle Time 30% lower;
- quantity of scraps due to non-compliance with customer specifications below 2%.
The graph shows a comparison between the performance of the two types of equipment:
comparing the first one in 2018 and NIM in 2019, there is an increase in real production capacity, that also considering the loss of time for scheduled stops, breakdowns, etc.
PUBLICATIONS, ARTICLES, AWARDS
D. Cascella, G.L. Cascella: “Polyurethane production meets digitalization” [AUTOMAZIONE INDUSTRIALE n.276 – ottobre 2019]
October 07, 2019
[…] To intercept all the benefits potentially offered by digital transformation and Quality 4.0, the design and construction of a polyurethane block production plant with operational headquarters in the United States were tackled.
The involvement of a multidisciplinary team of Italian suppliers (with skills ranging from electrical and automation systems, to the construction of robots and the creation of molds) has made it possible to completely reconfigure a classic plant according to the American regulations and standards UL 508A. , Nfpa 79, SAE-ISO-EN-DIN, Ansi B-11.
The coordinator of the project is the Apulian company New Wind Italian Bedding Technology, assisted by Mecprod for the construction of the plant and by Idea75 for the coordination of the project.
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
R&D and Innovation Manager in Idea75
MSc and PhD in Electrical Engineering
Politecnico di Bari (IT)
20+ y of experience in R&D and Industrial & Process Automation
20+ peer reviewed scientific papers on industry 4.0 and AI applications
Project Manager in Idea75
MSc in Industrial Engineering
Politecnico di Bari (IT)
4+ y of experience in the manufacturing business
The company NewWind S.r.l. was born in 1997 and from the beginning it stands out with its high standard of production and attention to detail.
Today the company produces 17 types of pillows and more than 40 types of mattresses, available in different sizes and adaptable to any type of need.
www.new-wind.it
Mecprod S.r.l. was born in Ostuni, in 1994. Thanks to an important network of national and international relationships, Mecprod has succeeded in consolidating considerable experience in the mechanical field. In 2009 the management wanted to diversify the activities carried out by Mecprod, investing resources in the green energy sector.
www.mecprod.com
