BELGIUM: A look at the world's top ten chemical giants reveals a surprising name. While Mitsubishi may be known to the general public for its cars and heat pumps, the Japanese group is also renowned in the chemical industry. From its Tielt facility (Belgium), Mitsubishi Chemical Advanced Materials (MCAM) produces high-performance plastics through extrusion. However, extrusion is a highly specific process that must run continuously, making downtime unacceptable. ATS assisted in developing a new electrical standard for retrofits, proved its capabilities by retrofitting several extrusion lines, and resolved a drive issue in record time by introducing the Danfoss iC7-Automation VFD.
What we make here is the cream of the crop in the plastics world. These plastics are used in demanding applications, such as aerospace, wind turbines, and semiconductor manufacturing. We can be proud of what we produce here, as only a handful of companies worldwide can do it.
PET, PEEK, POM C/H, TORLON... for those not familiar with the world of plastics, this list of abbreviations probably means little.
Plastic production is achieved through extrusion: a process that ideally runs 24/7. "It takes a significant amount of time to get production running smoothly again after a shutdown. Once a year, production shuts down for two weeks. Besides this planned maintenance shutdown, we ideally want to avoid any unplanned downtime," explains Vanderperre. MCAM has 55 extrusion lines of various types in Tielt, some even dating back to the 1960s. Guaranteeing reliability becomes increasingly difficult. At the same time, space is being made on the company site to install six new extrusion lines and increase capacity to 11,000 tons per annum (tpa). "They believe in what we do here. My primary role, therefore, is to bring our entire factory into the 21st century, and that begins with standardization. If the foundation is always the same, operation and maintenance become much easier," Vanderperre notes.
The challenge: Capacity upgrade to 11,000 tpa
ATS was tasked with developing a generic electrical schematic that would serve as the reference for every extrusion line: for retrofitting the old ones and building the six new ones. "On one hand, we wanted to guarantee reliable operation, and on the other, have robust process control over the line. This means having clear visibility into the operation of each line to enable better control." For the BU Automation and Project Manager Frederik Laevens, this was the first collaboration with MCAM. However, there was prior experience with the ATS Group: the Medium Voltage BU, VDC Roeselare (electrical components), and Ohmewatt (electrical resistors) were already known in Tielt. "The first time is always a bit of a discovery process: what is important to the client and how can we best install it? We start from the existing situation. All the line functions were listed like a menu. In consultation with the client, we could then determine what would be standard for all lines and what would be specific to each."
New approach to retrofit
It was a complex web to untangle. Depending on the plastic and the desired thickness, the extrusion process can vary enormously. Laevens: "By selecting and combining functional blocks, various configurations of extrusion lines can be built in a standardized way. And that pays off. Where three control cabinets were sometimes required in the past, it can now be done much more compactly." ATS was able to prove its new standard in practice: it was assigned the construction of an extrusion line. Everything went off without a hitch. The success led to a new assignment for the retrofit of two nearly identical lines (lines 13 and 15). "You always run into a few challenges. But it helps that you have many services in-house. Our Mechatronics team, for example, was responsible for the mechanical adjustments to the frame and belt drive to make the new motor fit the existing extruder frame," says Laevens.
Need for high-torque VFD
During the retrofit of another line, however, a 'new' problem emerged. Vanderperre explained the crux of the problem. "Extrusion is a low-speed process that requires high torque. Because of this, many variable frequency drives (VFD) fall short. For the line in question, it involved the smallest motor we have here, making this control even more challenging. The previous VFD manufacturer had provided a workaround by adding an encoder, but the line had never really worked quite as we envisioned. The problems were especially apparent during startup." This was no different after the retrofit: the motor would not turn. After four days, the previous VFD manufacturer could not solve the problem, so MCAM consulted ATS.
The solution: iC7 motor control for high torque at low speed
The emergency call landed with Gianni De Greve, Account Manager for Danfoss at ATS. Since 2023, ATS has been an official partner of Danfoss Drives, and De Greve acts as a liaison. "I try to match customer challenges with the right technical solution. I knew immediately that for a technically challenging application like at MCAM, the iC7 drives are often the right solution." The Danfoss team was ready and went to Tielt with ATS. In record time, they presented and tested the technical capabilities of the iC7-Automation, which performed beyond expectations.
Thanks to the superior motor control of the Danfoss iC7 drives, even at low speeds, we succeeded in keeping the motor under control in open loop - that is, without an encoder - under demands that were many times more severe than expected.
Benefits of iC7-Automation
The choice of the iC7-Automation VFD was no accident. This drive is specifically designed for demanding applications like those at MCAM, where precise motor control with high torque is crucial.
- The power of the iC7-Automation lies in its superior motor control, which delivers exceptional performance even without encoder feedback - in open loop
- Additionally, the drive is 'secure by design' thanks to a built-in crypto chip. Its superior protection against unauthorized access is essential for Industrial IoT and the future-proof standardization MCAM is pursuing
- The modular and compact design of the drive ensures a small footprint, while the wide power range and flexible configuration options mean the drive can be customized for almost any extrusion line
The outcome: Staying one step ahead
Vanderperre can only agree. After less than four hours, the line was running at full torque with the new drives. The two new lines now being planned will also be equipped with iC7-Automation drives. What did Vanderperre appreciate about the collaboration? "When I ask ATS to build a new panel, they do it to the highest professional standard. That in itself is an achievement these days. But not only do they build, they also ensure the panel is installed, that all the wiring is correct, that the motor is properly adapted... That makes them such a good match for a company like ours that wants to move quickly. Moreover, they keep their finger on the pulse of new technology. Because we are a market leader in what we do, we also expect our partners to be at the forefront. With the Danfoss drives, they have proved that they are." Vanderperre concludes.
ATS and Danfoss: Partners in variable speed control
ATS and Danfoss are no strangers to collaboration. For years, they have worked together to realize the best possible solutions for customers in the field of variable speed control. This collaboration was sealed with an official partnership, established in 2023.
We may be a manufacturer, but we also want to make a positive impact with our application knowledge and support. That's why it's so important to work with a partner like ATS. They are the extension of our technical expertise on the customer's shop floor for all first-line support: from advice to maintenance and repairs.
Related products
- Superior low-speed performance due to new original control algorithms
- High torque accuracy with 0-370 Hz frequency adjustments
- Load drooping feature provides even power distribution and consistent performance
- Ability to boost DC voltage with AFE system
- Combines high torque and power in a compact design to minimize footprint
- Designed with Safe Torque Off (STO SIL3) as standard for enhanced safety
Learn more
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