We realize that companies that are determined to effect a transformation in their manufacturing processes face critical situations on a daily basis and rely on reliable and timely indicative information vital to their operations.

Despite this, in some factories it’s still not unusual to come across someone responsible for checking each kiln by making a note of the readings and chalking the numbers up on a blackboard several times a day, when in actual fact this information changes every second and any variation could wreck the entire production run.

This manual process has worrying consequences, as it presents a significant production risk and also valuable work time is lost in having employees taking these readings instead of being dedicated to getting on with more profitable tasks.

It’s for this reason that our NUTEC Bickley kilns incorporate a Supervisory Control and Data Acquisition System, better known as ‘SCADA’.

At this point, we’d like to talk to you about the features of this system and how it’s able to help you operate your kilns more efficiently at the same time as optimizing labor costs.

What is a SCADA system?

• Sensors
• PLCs
• Scales

This application stores all the information entering the system and automatically analyzes – in real time – the correct process operation, enabling comparison with previous firing data in order to come up with possible improvements.

The benefits of SCADA in our industrial kilns

Some of the advantages of a data control system that can be fully integrated with your plant’s kiln operation are:

1. Obtain information leading to better process traceability

This application stores a history of the kilns’ different operational configurations, so that when there’s a case of optimal performance one can extract all data relating to how that was achieved and replicate those conditions, such as:

• Frequency inverter configuration
• Burner output
• Motor speed
• Temperatures and cycles
• Oxygen levels in the kiln
• Pressure settings
• Fan status

2. Storage of performance data in order to correct quality problems

Having a historical record of readings will allow for the timely correction of faults that adversely affect production quality. Here are a couple of examples:

• When producing sanitaryware this can result in a more opaque finish than normal. The SCADA system will help pinpoint the cause: a fluctuation in oxygen levels, a wrong change in the burner configuration, etc.
  
• If an operative starts their shift 10 minutes late, information is provided on how this holds up production and what the cost implications of this are to the company.

3. Creating a smart maintenance regime and decreasing downtime

With a SCADA system it’s possible to come up with an intelligent maintenance procedure thanks to the implementation of solutions that avoid future problems from cropping up and that execute corrective actions at the most appropriate time.

4. Making operatives’ jobs easier by having graphical statistics presented in real time

This application provides the most important operational information from all sections of the kiln, with detailed readings displayed in real time, these being some of the most critical:

• Temperature in each control zone of the kiln
• Gas consumption
• Fan output status

5. Achieve a more connected operation and take the next step towards Industry 4.0

With the new digital revolution, companies and their operations are fully automated, thus enabling them to benefit from real time readings and performance or future needs predictions.

Our SCADA system technology – allied to its web application potential – provides companies with a greater connectivity and access to smart data anywhere in the world.

• Log-in access to reports on your operation, direct from your laptop, smartphone or tablet.
  
• Make adjustments and implement solutions from absolutely anywhere.
  
  

Via the app, we support our customers in the monitoring of their kilns in order to control their operation, while they too can monitor them remotely and view kiln readings on their mobile devices. All this happens without needing the kiln manager to travel back to the factory late at night in the event of an unforeseen problem.

Modernize your own production systems with our smart kilns

By maintaining a record of all your plant statistics, the SCADA system enables you to improve production quality, prevent unforeseen failures and avoid downtime.

As you can see, this technology is extremely useful when it comes to production units, maintenance strategy and the operation of quality departments in all those manufacturing sectors that undertake critical processes, such as:

• Sanitaryware
• Technical ceramics
• Activated carbon
• Abrasives
• Electroporcelains
• Foundry products
  
  

In summary, if you already have the best type of kiln in your factory, the next step is to fully exploit its potential – by making sure you have the very best control system fitted. Confidently enter the new era of automation and benefit from intelligent manufacturing with the support of NUTEC Bickley systems.