Retrofit: renew the electronics and control, keep the mechanics

The mechanics of the roller mills from the 1980s and 1990s are excellent and remain repairable. After 30 to 40 years, however, the electronics, sensors, hydraulics and cooling are a risk of unplanned downtime. A retrofit starts there: sensors, drives and control are modernised step by step without touching the mechanics.

Retrofit TLS: the dry-run protection. Developed in-house by Walzpunkt AG, it fully replaces Bühler’s old SEL and SELA systems. Two infrared industrial cameras (ifm O2D522) check the chocolate film on the top roll. If it breaks, the machine stops after 5 to 8 seconds, before the rolls burn. Two laser distance probes monitor the material feed on rolls 1 and 2 and control the feed flap. Operation and control: Siemens KTP700 Basic with Siemens LOGO!. Installation by 2 technicians takes 3 to 5 days including production support, with the machine standing still for about 2 days. Delivered as hardware only or as a complete integration.

Retrofit Max: the complete conversion. A new Siemens touch HMI, a new PLC, PROFINET for sensors and actuators, frequency converters for the main motor and servo drives for the roll adjustment. The hydraulics and water cooling are renewed, TLS and the emergency stop circuit are integrated. Hardware, software and project coordination come from one source. Realisation within 4 to 8 months, conversion on site 3 to 4 weeks, cost about 25 % of a new machine, service life afterwards 10 to 20 years.

Single building blocks. The WALZPUNKT PSU 1 directly replaces old ±10 and ±15 VDC power supplies (1:1). These heat up the machine cabinets considerably and shorten the life of the electronics; the PSU 1 is stronger, runs more stably and produces far less heat. For conversions we supply and program modern control components: Siemens LOGO!, the AM2 AQ expansion module for analog outputs to existing controls, LOGO! Power and the KTP-700 Basic HMI.

For which machines. The focus is on Bühler roller mills of the Stoos, Rigi and Säntis series (SFLE 1300, 1800 and 2500), pre-refiners and fine refiners, plus production machines of every kind.

Warranty. For retrofit work performed on site, the warranty period is 6 months from acceptance.

Enquiries. By phone on +41 55 424 91 50 or by e-mail to contact@walzpunkt.ch.

More on this: Retrofit TLS · Retrofit Max · WALZPUNKT PSU 1 · HMI KTP-700 Basic · LOGO! · AM2 AQ · Contact