Engineers at Axion Consulting have developed a data logger for continuous process plants that helps operators to understand and eliminate causes of downtime.
This would potentially save them thousands of pounds a year.
The monitoring device has cut downtime by 50% at Axion’s Shredder Waste Advanced Processing Plant at Trafford Park, Manchester, which produces high-quality recycled polymers from end-of-life vehicles.
Although developed for the waste industry, the data logger is also suitable for other continuous processing industries with similar characteristics.
Capable of working with existing programmable logic controllers (PLCs) from different manufacturers, the logger provides hard data of a plant’s downtime and its causes, allowing operators to analyse faults and focus on systems improvements. A key feature prevents an operator restarting the plant until a stop cause has been logged.
For multi-site operations, the device makes it possible to compare sites and the performance of sites or shifts, with the benefit of remote data access when logged in.
Installing the data logger on four PLCs at Trafford Park is already delivering benefits for Axion, which is offering bespoke versions configured to individual client requirements.
Axion director Roger Morton said: “Since using the data logger, our downtime has dropped by around 50%, so it has been a worthwhile investment for us.
“It could also be of huge benefit to other businesses, so that is why we are sharing our expertise with external clients. Accurate monitoring of our processes has already helped to create savings and identify where we can implement improvements in our processes.”