Optimizing the production process is a never-ending task for plastics manufacturers like Renolit. This makes process traceability and reproducibility key requirements. VEGA’s innovative level and pressure measurement technology are underpinning Renolit’s work towards climate neutrality.
A true all-rounder for level measurement: VEGAPULS 6X – the radar sensor used by Renolit both for liquids in small IBCs and bulk solids in the outdoor 23 m high silos. Image Credit: VEGA Grieshaber KG
Renolit's plastic films are produced according to individual recipes that best meet customer requirements. These films, and the company’s other products, represent the highest level of functionality.
This necessitates highly accurate dosing of base materials, including polymers, additives, and colorants, under consistent ambient and process conditions. VEGA sensors for level, flow, and pressure are important in these settings.
Plastics production is also highly energy-intensive, making it increasingly important to measure energy consumption.
Universal Level Measurement Technology
Renolit stores raw materials in intermediate bulk containers (IBCs) for liquids with a capacity of 1000 L, or in large outdoor silos for bulk solids with a capacity of up to 200 m3.
Levels of stored materials must be monitored with millimeter precision, without the need to modify or open the containers themselves. Radar-based level measurement technology can meet these needs.
The VEGAPULS 6X universal radar sensor can be used to monitor a wide range of measuring points, ensuring that the appropriate quantities of each component are always supplied.
Simplifying Procurement Using Universal Radar Technology
Double security: On this process vessel, a VEGAFLEX 81 guided radar sensor ensures precise interface measurement, and a VEGASWING 63 vibrating level switch provides reliable overfill protection. Image Credit: VEGA Grieshaber KG
Procurement has become much easier for Renolit since the company began using VEGAPULS 6X in all its storage facilities. Silo configuration and the materials stored vary depending on specific product requirements; all materials must be optimally stocked to ensure production runs efficiently and uninterrupted.
Saving Energy via Flow Measurement with Pressure Sensors
Optimal raw material storage is just one area offering considerable savings potential. The direct measurement of energy use is also becoming increasingly central to Renolit’s business.
Renolit hopes to achieve CO2-neutral production by 2045. Currently, it has over 300 pressure meters monitoring electrical energy consumption in PVC film production.
An example of this is the calendar rolls’ temperature control units, which depend on three VEGADIF 85 differential pressure transmitters. This precise pressure instrumentation is used to accurately monitor the flow of heating water, ensuring the process runs under optimal conditions and that consumed thermal energy is precisely matched to demand.
Sensor Replacement During Ongoing Processes
Economical and accurate pressure measurement technology: To ensure product quality, the flow rate of heating water is precisely monitored with VEGADIF 85 differential pressure transmitters. This measurement also guarantees that the thermal energy input precisely matches the requirement. Image Credit: VEGA Grieshaber KG
Each VEGADIF 85 differential pressure transmitter is mounted with a gate valve, allowing it to be serviced or replaced without interrupting the current process.
The instruments’ special dual-chamber electronics offer additional savings potential. For example, static pressure and differential pressure can be measured simultaneously using two VEGADIF 85 sensors. This approach offers notable benefits because static pressure is an important component for optimal process flow in the calendar.
With the deployed pressure measurement technology, this can now be monitored without additional sensors.
Tracking High Energy Demands
Renolit has reduced energy loss by 60 % using new software modules to optimize the standby mode of all electrical devices. To further reduce consumption, the company performed significant optimization of remaining high-energy processes, such as cooling and heating.
Renolit will continue to leverage VEGA’s level and pressure instrumentation in the future, relying on precise, reliable measurements to ensure traceability and indicate where and when the plastics were produced, along with the speeds and temperatures.
Acknowledgments
Produced from materials originally authored by VEGA Grieshaber KG.
This information has been sourced, reviewed, and adapted from materials provided by VEGA.
For more information on this source, please visit VEGA.