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Integrated safety system solves e-stop problem

Outdated drives, relay logic and PLCs running on proprietary software, which was making them increasingly difficult to operate, maintain and support

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Though segregated systems still predominate, many companies are taking steps toward integrating safety and control systems—and reaping benefits.  Evergreen Packaging, Memphis, Tenn., is one of them.

At its Olmsted Falls, Ohio plant, Evergreen Packaging produces milk cartons from rolls of paperboard supplied by one of its paper mills. The plant uses eight sealers and converting machines to fold, print, die cut and seal the cardboard cartons. The high-speed converting operation is capable of producing cartons ranging from 4 ounces to half gallons, with an average output capacity of approximately 400,000 cartons per hour.

Over the years, Evergreen machines have employed a mix of control technologies from different suppliers. Most recently, the machines consisted of outdated drives, relay logic and PLCs running on proprietary software, which was making them increasingly difficult to operate, maintain and support.

To make changes to the machines, engineers had to perform complex reprogramming for each new control function.  Access to reliable support also was a growing concern, as the company was finding it increasingly difficult to find engineers with the knowledge and skills needed to support the older, diverse technologies. In addition, limited diagnostic capabilities made troubleshooting an ongoing challenge.

Another area of complexity centered on the extensive amount of wiring required with the existing control system design, which complicated maintenance and repair, and multiplied the potential points of failure.

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