PREFORM PRODUCTION PETplanet Insider Vol. 26 No. 06/25 www.petpla.net 35 changeover times by up to 65%, enhancing the overall efficiency of the plant and reducing downtime between production runs. Minimal maintenance: The design of the DRV system has been designed for minimal maintenance, ensuring fewer interruptions and higher operational uptime. Energy efficiency and sustainability considerations Energy-efficient technologies and sustainability were key design priorities in the development of the plant. Technologies such as vacuum drying, gravimetric dosing, and automated transport systems contribute to lower energy usage and operational costs. The use of rPET in preform production reduces the reliance on virgin materials and aligns with broader regulatory and market pressures towards circular economy models and environmentally sustainable practices. Integrated control systems The plant’s operations are managed by a Siemens S7 PLC, which coordinates the various subsystems, ensuring seamless interaction between each component of the production line. This integration ensures that material handling, dosing, drying, and other processes are synchronised, reducing the potential for errors and optimising production efficiency. The touchscreen interface provides operators with real-time access to all critical process parameters, allowing for any necessary rapid adjustments to be made. This real-time control enables operators to monitor and finetune operations, ensuring high production quality and minimal downtime. Additionally, the company states that the system’s data collection and diagnostics capabilities facilitate predictive maintenance, ensuring that any potential issues are addressed before they result in production stoppages. Predictive maintenance PET Solutions’ predictive maintenance system is engineered to reduce unplanned downtime and optimise the performance of production lines. By leveraging a network of advanced sensors, the system continuously collects real-time data on the operating conditions of each machine and plant component. This enables the early detection of anomalies and the identification of potential failures before they occur. Through predictive data analytics, maintenance activities can be scheduled in a targeted and efficient manner, minimising emergency interventions and extending the operational life of equipment. This approach is claimed to lower operating costs while enhancing system reliability and ensuring consistent production flow. Traceability across the complete supply chain The facility includes a traceability system that tracks raw materials through to final product delivery. This system provides digital documentation of each stage of production, enabling better inventory control, improved transparency, and compliance with quality and safety standards. This enhances transparency across the entire supply chain, effectively addressing the increase in customer demands for safety and sustainability. Operational performance The combination of automated material handling, precise dosing, energy-efficient drying, and integrated control systems contributes to a consistent production of rPET preforms. The facility is equipped to address the challenges associated with processing recycled materials, which can vary in quality, while maintaining stable output and cost efficiency. The commissioning of this plant highlights ongoing efforts within the packaging and beverage industries to adopt more sustainable production methods. While PET Solutions implemented the system, the technologies and practices employed are indicative of a wider shift towards automation, traceability, and environmental responsibility in rPET processing. www.petsolutions.it Continuous vacuum drying technology
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