Pulsar Engineering, which is part of the Pulsar Group, specializes in the engineering and manufacturing of machines and lines for packaging and conveying of tissue products and in-line quality control systems. The Group includes the commercial facility in Green Bay, USA where there is a wide demo room for customers to see and test many of its products first hand and the brand new Chinese branch, Pulsar Shanghai, inaugurated in July 2019. Pulsar Engineering holds over 89 patents and patents pending around the world for its technologies and innovations.
In recent years, Pulsar Group has launched many solutions dedicated to the tissue industry, focusing on the “Industry 4.0” concept for the creation of the “smart factory”.
In this specific case, Pulsar approach to Industry 4.0 is based on the concept of Digital Twin, which is the exact copy of something real. This can be physically (3D models) or virtually reproduced (discrete element simulation). In both cases, it represents something real that is digitally replicated with the aim of simulating a process, in order to check its functioning.
The Digital Twin is an exact copy of real object or process on which performing tests and trials. The purpose is to avoid issues implying unexpected costs. Checking every possible problem in a preventive way leads to a process efficiency that helps organizations to be more profitable.
The Digital Twin helps putting in practice the Industry 4.0 concept of SIMULATION.
For this specific purpose, Pulsar Engineering has created and developed a simulation service called DYNAMIC PLS (PLANT LAYOUT SIMULATOR).
DYNAMIC PLS reconstructs a model with the technique of discrete elements (schematization of a system as a set of elements connected to each other through contacts between them) and recreates the behavior of Tissue plants and processes in a logical manner, evaluating its functionality and efficiency (OEE).
DYNAMIC PLS predicts the functional behavior of a new line before its physical construction, allowing customers to reduce risks and costs.
Moreover, it optimizes also the existing plants and helps evaluating the effects of changes on the line, without having to operate directly on the machines.
The main benefits and results that can be achieved through the simulation service are:
1. Virtual duration of the simulation starting from a working shift until reaching one year of production
2. Calculation of the overall production of the line per product unit (rolls, packs, bags, bundles, cases and pallets)
3. Calculation of the average and instantaneous speed of the machines
4. Calculation of raw materials used for production (i.e. quantity of tissue and related raw materials)
5. Identification of bottlenecks with indication of the machine or the group that limits the maximum speed of the system
6. Calculation of line OEE (in particular the values of line and machines exploitation)
7. Customization of a production plan with different products run, considered the changeover times (the software takes account of the time required for the restocking of consumable materials – mother reel and polyethylene reel change, etc.)
8. Comparison between different layouts, operational logics and alternative machines to evaluate the efficiency and the productivity of the line with different products
9. It is an effective training tool for line operators (with check of machines’ regulations during a determined period of time and related consequences)
Once defined the parameters to set the software by Pulsar specialized engineers, the user is be able to manage independently the production line simulation thanks to a user-friendly interface.
“At Pulsar Engineering, we do not only believe in innovation, we believe in the integration and cooperation between people, organizations and nations. We work alongside our customers in the process of production lines in the tissue converting industry to create top of the line machines, equipment and software that work together to increase product quality and improvement of everyone’s standard of living.”
