Converting Projects
Project Objective: Plant Wide Process Assessment & Automation Plan
Customer: Specialty Converter, Eastern U.S.
PCT provided:
• On site evaluation of all major process
equipment and material handling systems
• Interviews with production, maintenance,
engineering, and management staff
• Development of a plant wide automation
plan
• Recommendations for equipment and
process modifications
• Estimated costs and schedules to
complete modifications
Project Objective: Improve the Performance on Several Slitters
Customer: Midwest Location of Major Blown Film Producer
PCT provided:
• On site evaluation of the slitters in order to
take measurements, observe machine
operation, and gather drawings and
program files
• This evaluation considered input from
engineering, maintenance and operations
• Modifications to the slitter speed and
tension control logic as required
• Added taper tension control to improve
finished roll quality
• Minimized lay on bounce
• Optimized slitter for lock core winding
• Retrofit existing controls and drive to
modern equipment
• On site commissioning support for starting up and tuning the new control program
• On site support for initial production at which time PCT continued to refine the system tuning
© 2007 PCT Engineered Systems LLC. All Rights Reserved
Project Objective: Upgrade Single-Layer Extruder to 7-Layer Extruder
Customer: Midwest Location of Major Blown Film Producer
PCT provided:
• Integrated system for control of the blending system,
vacuum pump, and extruder
• (7) multi-bay control enclosures including PLC,
drives, SSR’s and power distribution
• New operator stations
• Programming for the PLC, HMI, and drives
• Onsite commissioning and support
Project Objective: Supply of a Complete Electron Beam Process Line
Customer: South American Location of a Major Film Producer
PCT provided:
• Final design, fabrication, assembly and testing of turret
unwind, splicing station, chill roll stand and turret rewind
• Refurbishment, modification, assembly and testing of a
BroadBeam electron beam processor
• Integrated line control system including PLC’s, drives
and operator stations
• Shop testing of the entire line including training of
operators from the plant
• On site installation and commissioning support
Project Objective: Modify Slitter Mechanics to Improve Reliability
Customer: Midwest Location of Major Blown Film Producer
PCT provided:
• Engineering study to recommend mechanical
changes
• Created a pass line drawing from customer
drawings
• Simplified the pass line by removing several rolls
and developed alternate thread paths for the
system
• Replaced 4 rolls in the unwind section based on
engineering discoveries
• Replaced 3, high inertia, “billy rolls” with a single,
low inertia roll
• Modified upper fold board roll for load cell mounts
to provide appropriate tension feedback
• Replaced the nip roll mechanisms with driven Swrap rolls
© 2007 PCT Engineered Systems LLC. All Rights Reserved
Project Objective: Upgrade Line Drives and Reeler Control Systems
Customer: Midwest Location of Major Blown Film Producer
PCT provided:
• Engineering study to recommend electrical and
mechanical changes to the winders on 5 blown film
lines
• Upgraded the winding control equipment which had
become increasingly difficult to maintain
• Upgraded the slack take up system power train and
control which was a safety concern
• Provided mechanical design of the new motor and
gearbox mountings
• Complete turnkey electrical change over and onsite
startup assistance
Project Objective: Support for a New High Performance Film Treating Line
Customer: Major Film Producer
PCT provided:
• Detailed sequence of operation document
• Complete OEM coordination for multiple pieces of machinery
• Detailed specifications for proposal solicitations for winder,
unwinder, and thermal control systems
• Integration of OEM machinery
• Design and programming of master line controller
• Development and programming of the line’s HMI system
including a “recipe” management function and integration with
the plant production data logging software
• Supply and population of a control house containing power
distribution and drive equipment
• Onsite control system checkout and product qualification
8700 Hillandale Road
Davenport, IA 52804
563.285.7411
FAX 563.285.7433
The Solutions Team
© 2007 PCT Engineered Systems LLC. All Rights Reserved
www.teampct.com
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