Gefran improves the efficiency of Macchi extruders

Macchi, one of the world’s leading manufacturers of blown film plants, has adopted a complete package of Gefran-branded solutions to improve the production efficiency of its extruders. In particular, the Melt pressure sensors with IO-Link digital output have optimised the entire extrusion process, including from an Industry 4.0 perspective. These sensors allow for precise detection of the fluid pressure, even at high temperatures, which is essential for maintaining the quality of the finished product.

The IO-Link interface also allows a series of essential data to be acquired for the purposes of predictive maintenance. Information such as the maximum recorded pressure and temperature peaks, the total number of hours the sensor has operated under pressure and the calibration threshold deviations allow for the development of algorithms capable of ensuring better productivity while guaranteeing a longer extruder lifetime.

To reduce the emissions generated by its manufacturing processes, Macchi has replaced mercury-filled probes with environmentally-neutral versions. The chosen solutions were the ILI series, with innovative IMPACT technology without filling fluid, with a diaphragm thickness 15 times greater than the standard versions, and ILK, with sodium-potassium mixture filling.

To complete the process of digital transformation of the installed sensors, the Macchi plants have been equipped with Gefran’s WPL series position transducers featuring HYPERWAVE magnetostrictive technology and IO-Link digital output. These sensors can simultaneously record a large number of parameters in accordance with Industry 4.0 protocols while guaranteeing absolute linear precision even in the presence of shocks, vibrations and electromagnetic interference.

Gefran Soluzioni guarantees integration of all the systems that make up the extruder, complementing the supply of components with a high-quality consultancy service for the design, development and construction of electrical panels. It also provides constant support to Macchi’s R&D division in the development of dedicated multiplatform software for line management as part of an ongoing evolutionary process of management logic and process automation. One of the lines involved in this synergy is RECOTRIM, a unique pelletizing system designed to permit in-line recycling of the side trims produced during film extrusion.