As individual as your system – the very latest in automation technology

State-of-the-art control technology is a key part of the optimal operation of a batch plant. After all, it is responsible for the efficient, reliable and reproducible operation of a system.

More than 40 specialists are realising next generation automation and control systems. This means we are one of the few companies able to carry out full development and realisation in-house.

We offer:

  • Project coordination
  • E planning / hardware design
  • Software development
  • Switch cabinet construction
  • Installation and control panel construction commissioning
  • After-Sales service

Everything from a single source

We work very closely with the most important component suppliers, such as Siemens, Schneider and Rockwell, and so are able to leverage very quickly the latest developments for our control systems. But it is not until seamless integration of the systems into your overall production process that a perfect solution results.

Hardware design

We exclusively develop the functions of your plant using the latest E-CAD software such as E3.series and EPlan P8. The documentation and production documents are automatically created. Efficient workflow is ensured by using interfaces to our software development. So we have already put into place the conditions for maximum effectiveness.

Our services in the field of hardware design

  • Detailed analysis of the plant
  • Project management/coordination
  • Preliminary discussions with customers
  • Planning of control cabinets, electrical installations and network structures
  • Preparation of all necessary documents

Software development

Powerful software and its optimum system integration are key components in automation technology. This is because only the right software creates the optimum function that ultimately yields usable value-add.

Our services in the field of software development

  • Generation of the automation software (Siemens, Rockwell, Schneider, ABB, etc.)
  • Generation of the process control system (WinCC, Citect, Intouch, RSView, iFix, etc.)
  • Planning of communication concepts and bus systems
  • Software testing prior to delivery
  • Development of database applications
  • Interfaces for higher-level systems
  • Remote maintenance connection for teleservice

Control Panel construction

As the central control system, we supply cabinet solutions tailored precisely to your installation. For assembly, we rely solely on high quality components from our system partners. From integrated control panels, you have access to the different functions of your system and receive status messages in real time.

Weighing solutions

We are also a specialist in weighing system solutions. Our many years’ experience in developing and integrating precision weighing technology means we are also able to address particular requirements here in a professional and reliable manner.

Belt conveyor weighers, container scales, rotary hopper scales and micro-metering scales are some of our standard products.

Weighing electronics designed specially for the bulk material industry provide our customers with maximum flexibility. The customer decides between weighing indicators or weighing modules that can also control metering/weighing processes independently. For each application, we find the right solution.

Electronic load cell monitoring

ZIPPE Advanced Load Cell Monitoring enables the electronic monitoring of up to four load cells, thereby the manual measuring of electric signals is not necessary. Every load cell can be monitored individually to detect faults, defects and non-uniform load states.

ZIPPE Load Cell Junction Box (Z-LC-JB) replaces the conventional terminal box in which individual measuring cell cables converge. No additional voltage supply is necessary for load cell monitoring when it is used in conjunction with the Z-WI-102 weighing indicator and Z-WM-102 weighing module, developed specially for the glass industry.

Fault states of measuring cells can be signalled using a volt-free contact. The integrated graphics display shows the individual mV signals of the load cells and so assists startup and maintenance personnel in testing the scales.

Modernization

We offer modernization precisely tailored to your needs, that upgrades your systems so they are up-to-date and future-proof. We of course support you in the configuration, adjustment and optimisation of your system.

If you want to make your new system even more efficient and convenient, you can expand it with numerous new features.

  • Modern operating concepts - from redundant servers to mobile user devices
  • Remote access to the highest security standard
  • 24x7 support with remote maintenance
  • Reporting and analysis functions for continual system optimisation
  • Connection to higher-level systems (such as ERP)
  • Integration of new functions for monitoring, diagnostics and maintenance

Virtual startup and system simulation

Prior to delivery, our controllers are subjected to intensive hardware and software test phases - that also serve the purposes of quality control.

In our test facilities, hardware and software simulations of the actual installations are run. This enables the logic of the wiring and the PLC sequence program to be tested before the installation is brought online.

In this virtual operational scenario, actual production and installation parameters are used to bring about environmental conditions that are as close as possible to actuality. The complex correlations of the material flow are modelled and corresponding production data is generated. This enables unforeseen faults to be detected and eliminated prior to actual operation.

In this phase, the alarm system of the SCADA system informs the operator of discrepancies from the process parameters simulated and of any anomalies.

Factory Acceptance Tests (FAT) and customer training

As part of in-house Factory Acceptance Tests, we also offer our customers in-house training to familiarise them with the system controller and the relevant documentation. That enables the customer to get to know the simulated system controller and operation via the SCADA system prior to actual operation.

During the initial operation process, we hold on-site training for service and maintenance personnel as well as the plant operators responsible.