Case Study: High-Precision Extrusion Line Modernization

Increasing Production Efficiency and Reducing Scrap for a Major European Cable Producer
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1. Project Overview & Background

When off-the-shelf equipment cannot meet your complex production requirements, our R&D and manufacturing teams step in. We design, engineer, and build bespoke cable and wire machinery strictly aligned with your specific operational goals. From the first 3D CAD model to final on-site commissioning, we deliver robust, high-performance mechanical assets built to withstand the most demanding industrial environments.
The Client:
A leading cable manufacturer in Europe specializing in high-voltage industrial cables.
The Asset:
A 15-year-old, large-scale extrusion line that was the backbone of their facility but had become an operational bottleneck.
Objective:
To restore precision, increase line speed, and integrate the system into the factory’s central data network.

2. The Challenge: Legacy Limitations

Before Bemos Automation’s intervention, the client faced several critical challenges that threatened their market competitiveness:

Inconsistent Quality:

The aging DC drive system struggled with tension control, leading to irregular insulation thickness and frequent product rejections.

High Material Waste:

A staggering 12% scrap rate was recorded due to startup instabilities and synchronization errors.

Maintenance Nightmare:

Obsolete electrical components made it nearly impossible to find spare parts, leading to unplanned downtime that lasted days.

Lack of Data:

There was no real-time monitoring; management could only see production results at the end of the shift, making it impossible to react to live errors.

3. Our Engineering Approach: The Solution

Our team executed a multi-phase “Total Line Revitalization” strategy:

Phase A: Mechanical Restoration & Power Upgrade

Stripped the legacy DC motors and replaced them with high-response AC Servo Drive systems.
Conducted a full mechanical overhaul, including bearing replacements and realignment of the extrusion screw to ensure vibration-free operation at high speeds.

Phase B: Intelligent Control & Automation

PLC Integration: Installed a Siemens S7-1500 PLC to serve as the new “brain” of the line, managing complex synchronization logic between the pay-off, extruder, and take-up units.
Smart SCADA Interface: Developed a custom 15-inch touch-panel HMI (Human-Machine Interface). This allowed operators to save “Production Recipes,” ensuring that the same quality is achieved every time with a single touch.

Phase C: Safety & Compliance

Designed and built a completely new, CE-compliant electrical cabinet.
Integrated advanced safety sensors and emergency-stop protocols to meet the highest European workplace safety standards.

4. Technical Specifications

Control System: Siemens SIMATIC S7-1500 Series
Drive Technology: Multi-axis AC Servo Drives (Tension & Speed Control)
HMI: 15” High-Resolution Industrial Touch Panel with SCADA
Data Protocol: Profinet / OPC-UA for ERP Connectivity
Compliance: Full CE Certification & Machine Safety Directive 2006/42/EC

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5. The Results: Measurable ROI

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Increase in Line Speed:

The mechanical and automation upgrades allowed the line to safely operate 35% faster than its original factory specifications.
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Scrap Reduction:

Insulation precision reached +/- 0.01mm, dropping the scrap rate from 12% to below 2.5%.
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Zero Unplanned Downtime:

In the first 6 months post-upgrade, the line experienced 0 hours of electrical or control-related downtime.
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Month Payback Period:

The savings from reduced material waste and increased output covered the entire project cost in less than a year.

6. Client Testimonial

“Bemos Automation didn’t just repair our machine; they re-engineered it for the 21st century. The level of precision we now achieve with our 15-year-old line is comparable to a brand-new multi-million dollar installation.” — Production Director, European Cable Group

Is Your Production Line Reaching Its Limits?

Don’t settle for declining efficiency. Our engineers are ready to perform a technical audit of your legacy machinery and propose a roadmap for modernization.