Hosokawa Alpine presents automated and digital solutions to enhance efficiency and safety for blown film lines. These include digital start-up assistant, system monitoring system, and predictive maintenance tools.

With the modern software solutions from Hosokawa Alpine, film manufacturers can keep an eye on the operating status and productivity of their system at all times.

Assistance systems for easier system operation

The core of Hosokawa Alpine’s system automation is the ExVis process visualization software. It includes a start-up assistant for easier system start up. The settings for a film formulation are stored in the software, allowing operators to start up the system in four automated steps without having process engineering know-how themselves.

The company offers an operating device for the film take-off, which can be connected to the take-off or the collapsing system and operated on site, allowing immediate access to the connected component.

Automation solutions for increased efficiency and productivity

Hosokawa Alpine also offers automation solutions to optimize the use of their systems, speed up processes and measurably increase productivity.

This includes an automatically adjustable cooling ring insert. Here, the optimum setting for the cooling air supply can be saved and automatically re-started. The one-touch change included in ExVis includes preset format changes and reproducible settings for the collapsing system and side gussets.

The software package thus enables accelerated start-up of a film format and fast switching between different formats. This minimizes changeover times and the associated material losses and offers film manufacturers a high degree of flexibility.

Monitoring systems for smooth production

System monitoring system from Hosokawa Alpines immediately visualizes malfunctions in operation and production and enables them to be rectified quickly. A camera system with various cameras on the take-off, winder and MDO produces images that can then be called up via the operator terminal.

This enables an overview from the control panel, even in areas of the system that are not visible. In an emergency, the remote service from Hosokawa Alpine Blueserv, the company's service brand, can quickly access the system.

Predictive maintenance for machine diagnostics in real time

Predictive maintenance tool isa.guard from Blueserv can precisely predict maintenance requirement.

The predictive maintenance tool isa.guard helps to recognise anomalies at an early stage and intervene if necessary.

"Problems are recognised before they become critical or even arise. This allows customers to plan interventions proactively and maximise the uptime of their systems," explained Christian Hoffmann, Director of Blueserv Blown Film Extrusion.

By analyzing a wide range of data and sensors, isa.guard provides a real-time diagnosis of the machine's condition, providing full transparency about blown film production.

Modular software system for comparative analysis

The modular software platform isa.io enables a comparative analysis of process data to optimize performance and increase efficiency across all machines.

"This gives our customers an excellent overview of all Alpine blown film lines - including the option of carrying out targeted deep dives for detailed analyzes. Push notifications and many other functions can also be customized on request," said Christian Hoffmann.