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Búsqueda de socios para probar un dispositivo de optimización de procesos de fabricación


Oferta Tecnológica
Una pyme británica ha desarrollado un dispositivo de optimización de fábricas para mejorar el rendimiento de procesos de fabricación. Este dispositivo se conecta fácilmente a cualquier sistema de control y funciona de forma autónoma para mejorar la calidad de un producto y la productividad, además de reducir costes. El dispositivo permite monitorizar los datos de sensores de proceso y medidas off-line, como muestras de laboratorio, para tomar decisiones y enviar instrucciones. La empresa busca fabricantes en los sectores de alimentación, bebidas, petróleo y gas, pulpa y papel, tejidos, cemento y química para probar el dispositivo y establecer acuerdos de cooperación técnica.


Partners are sought to pilot a manufacturing optimisation device
This UK SME has developed a factory optimisation device aimed at improving manufacturing process performance. The device easily connects to any control system and acts autonomously to improve product quality and productivity, and reduce costs.

The company would like to enter into technical cooperation agreements with manufacturing partners involved in the food, beverage, oil and gas, pulp and paper, textiles, cement and chemicals industries to pilot the device.
This north-west UK SME was established in 2012 to provide process control consultancy and technical support services to companies working in the refining, petrochemical, chemical, energy, polymer, food processing, pulp and paper, and mining industries. Their services include process control fine tuning, benchmarking, technology selection, design and implementation.

The company has developed a factory optimisation solution aimed at improving manufacturing process performance. It is a hardware device with low footprint which easily connects to any control system to continuously monitor and analyse factory sensor data. The device sends instructions to optimise the process and allow it to run more efficiently.

The device supports manufacturing companies to increase profitability by helping manage costs, improve product quality and increase productivity. Constantly changing constraints make it challenging to run a process optimally using conventional controls. For example the sale price of electricity may change based on the time of day, or the market price of the products being sold might fluctuate. Using traditional operation strategies, human operators make very infrequent changes to processes and tend not to consider the changing efficiencies or economic models. The complexity and number of combinations are very difficult for a human operator to process on a real-time basis. The device acts as a control strategy which makes real-time adjustments to find the optimal combinations minute by minute. This way it drives the industrial process to the economic optimum point.

The device works by adapting an embedded model and tuning parameters to reflect the specific process under consideration. It monitors process sensor data as well as off-line measurements like laboratory samples to make decisions and send instructions. Also the device´s built-in optimisation engine uses knowledge of the economics of the process to move the process to the most profitable limits. The device continuously monitors and responds to disruptions 24 hours a day.

The benefits:
·Increased production: operating closer to equipment constraints giving improved productivity
·Lower operating costs: lower energy usage and less product give-away
·Improved product quality: reduces process variability and increase process capability
·Lower emissions: lower specific energy consumption, lower incidents of trips and better overall stability all contribute to lower environmental emissions
·Better operational reliability: better stability means less wear on production equipment

The features:
·The device´s virtual sensor feature acts like an online sensor. It is able to provide a continuous estimate of measurements such as laboratory samples or slow analysers
·The device comes with self learning technology
·Customisable web based operating graphics
·Secure real time data streaming to big data and analytic software in the cloud. Ready for the industrial internet of things
·Role based security so that operators and engineers can access the information assigned to them
·Supports a wide range of communication protocols including fieldbus, industrial ethernet and open platform communications (OPC)
·Industry standard IEC 61131-3 compliant (an open international standards for programmable logic controllers)

Although the company has case studies providing data on the benefits of using the device they are seeking companies in specific sectors to act as pilot projects to validate the device. The types of users required for the pilot cases are companies involved in the following manufacturing industries:

·Food and beverage manufactures (milk powder, sugar, coffee, etc)
·Oil -Y- gas
·Pulp -Y- paper

The company is looking to enter into a technical cooperation agreement to work with a manufacturing partner to pilot the device. This agreement will include the installation, set up and monitoring of the device.
Advantages and Innovations:
Reliable, safe and secure:
· The run time environment used has been deployed in thousands of industrial applications across the world. Its reliability is well proven
· The device is designed with cyber security as a fundamental part of the architecture, not just bolted onto it

Low maintenance through self-learning:
· The device has a capacity to create, record and learn from data to continuously assess and improve the model of the process being used. This means the device adapts to changes in the plant and delivers sustained benefits without a need for significant maintenance.
· The device is constantly learning and further to this is stimulating the process to create the data it needs rather than relying on steady state data

Versatile, light and intuitive:
The device is appropriate for a wide range of applications and integrates easily within any control environment:
· Developed in industry standard IEC 61131-3 language
· Supports a range of communication protocols
· Employs fast optimisation techniques that permit high execution frequencies
· Default tuning parameters work out of the box
· Includes tools to quickly build models of the process
· Modern, intuitive user interface facilitates ease of use

Delivers maximum results:
· The proprietary algorithms used reduce variability in a process much further than traditional methods are capable of
· The device is able to safely push the process to its limits and to get the maximum of the process
· Reduces stress on plant operating staff
Stage of Development:
Available for demonstration
Secret Know-how
CommeR Statunts Regarding IPR Status:
In the process of applying for a patent

Partner sought

Type and Role of Partner Sought:
The company is seeking manufacturing partners to pilot the device. Partners should aspire towards continuous improvement of their manufacturing processes specifically focusing on reducing costs and improving efficiencies.

The partners should be a manufacturer involved in the following activities:

· Food and beverage manufactures (milk powder, sugar, coffee, etc)
· Oil and gas
· Pulp and paper
· Textiles
· Cement
· Chemicals

The partner will be required to pilot the device for an agreed period and provide data on performance and cost saving improvements.

In return the north-west UK SME will deliver the following:

· Before installation undertake a site survey and provide a benefits report
· Install the device which includes modelling, commissioning and optimising settings
· Provide regular monitor reports assessing the effectiveness of the device
· Report the main achievements at the end of the study

The companies will enter a technical cooperation agreement to work together to pilot the device. If the device is proven to provide efficiency improvements to the partner, then there will be an option to enter a commercial agreement with technical assistance to continue using and benefiting from the system.


Type and Size of Client:
Industry SME <= 10
Already Engaged in Trans-National Cooperation:
Languages Spoken:


Technology Keywords:
01003008 Data Processing / Data Interchange, Middleware
04007001 Gestión de la energía
02003005 Information processing & Systems, Workflow
04007003 Optimización de procesos, utilización de energía residual