The efficiency improvement of BOPP film production line by automation transformation can reach 15%~30%, which depends on the coverage of the transformation module and the basic status of the original production line.
1, The core basis for efficiency improvement
The proportion of effective operating time has increased: unplanned downtime caused by manual coil replacement, parameter adjustment, and defective product handling has decreased from 8% to 12% of the original manual operation to 2% to 5% after automation transformation, directly increasing the actual production time.
Improvement in rated speed compliance rate: Online tension, temperature, and pressure closed-loop self-control replaces manual adjustment to avoid speed reduction and film breakage caused by process fluctuations. The rated speed compliance rate of the production line has increased from 82% manually operated to over 95%.
Raw material and loss optimization: The accuracy of the automatic batching system is controlled at ± 0.2% (manual control is ± 1.5%~2.0%), reducing raw material waste; Online defect detection and elimination reduces subsequent rework losses. 2, Differences in Improvement among Different Renovation Plans
Partial automation (only replacing manual operations): such as automatic roll changing, automatic slitting, and online defect removal, with an improvement of about 15% to 20%.
Full process self-control transformation (including process linkage control): such as batching system, adaptive adjustment of longitudinal/transverse tension, and die head pressure linkage, with an increase of about 25% to 30%. 3, Constraints on actual improvement
Original production line status: New production line renovation within 5 years of service life, with a stable improvement rate of 20% to 30%; Old production lines with a service life of over 10 years need to replace aging transmission components synchronously, otherwise the improvement rate will only be 10% to 15%.
Adaptability of the transformation: It is necessary to match the mold head and stretching equipment interface of the existing production line. Compatibility failures will offset about 5% to 8% of the efficiency gain.
