Optimisation of production performance through the digitalisation and automation of processes, with a significant reduction in waste and resources used
PRTR Call for Proposals Project
The project is based on the automation and digitalisation of the banbury (internal mixer), used in the development of pre-dispersed rubber in the footwear sector. This process includes the improvement of auxiliary systems such as water cooling, or the final management of the product, which will allow greater production performance to be achieved with a significant reduction in the waste generated and indirect costs. The effective control of the environmental resources used, the reduction of losses and losses, together with technological modernization, is essential to maintain profitability and competitiveness in an increasingly demanding market. One of the most effective ways to keep track of all these processes is by optimizing production and logistics processes. To this end, a new SCADA automation and digitalisation system will be implemented, which will allow production processes to be managed more precisely, optimise resources and reduce downtime. In addition, a new refrigeration refrigeration unit will be implemented that will thermally control all the predispersion lines in a more efficient way. This new installation represents a sustainable improvement over previous cooling towers, as it reduces the consumption of water used, eliminates its subsequent discharge into the treatment plant, eliminates its treatment with chemical substances such as biocides or chlorine/bromine, and also avoids the risks of legionella. In short, the installation of both equipment will have an impact on a clear productive improvement of our processes in a more eco-sustainable way.
Line of action:
Private sectorStatus:
En ejecuciónLocation:
Calahorra (La Rioja)Geographic scope:
EspañaLine of research:
Digitalization to innovate in terms of processes and organizationExecution date:
2024End date:
2026Duration:
01/09/2024 – 31/12/2026Total budget:
435,114.55 eurosAmount of aid from the Biodiversity Foundation:
217,557.28 eurosThe main objective is the digitalization of the internal mixers used for the development of predispersed (additives used in the rubber soles of footwear), through the inclusion of specific software that allows all stages of the process to be controlled. This will reduce the need for reprocessing of the mixtures, as well as the losses and losses generated in the processes, thus reducing the waste produced. The development of optimised materials will be favoured, with more efficient control of machinery, in real time and more modern tools that allow the monitoring of the process. In addition, a new water cooling system will be introduced for the mixers, helping to reduce the amount of water and the environmental impact. These improvements will also drive the development of materials optimized to meet market demands. In addition, an improvement in the quantification of emissions will be implemented throughout the value chain of the process. With this project, the entity proposes two results: 1. improve its environmental footprint, in terms of reducing energy costs and direct labour in all pre-dispersing lines (they intend to reduce 95% of reprocessing hours, with the consequent reduction in expense, which they do not quantify), reduction of downtime and increase in the productivity of the pre-dispersing lines (it is not quantified by how much they will be reduced), and the reduction of organic chemical residues by half compared to previous years (from about 63,305 kg in 2023 to 31,652.5 kg after the project); and 2. Reduction of process waste generated by 95%. The indicators proposed will be the reduction of water consumption, suppression of biocides and other chemical products for water treatment (not quantified) and reduction in energy consumption, from 3,000 V to 400 V.
Optimisation of production performance through the digitalisation and automation of processes, with a significant reduction in waste and resources used
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