Catael and Unilin: fastest laminate press

Reprogramming from scratch

Unilin wants to produce in an ever more efficient, smart and flexible manner. This means starting up production lines quickly, resolving incidents right away and implementing changes smoothly. This therefore requires not only a top-notch machine, but also powerful, smart software.

“With the existing operating system, each customisation required many weeks of engineering,” Sammy says. “Troubleshooting and maintenance were complex. To deploy the advanced Wemhöner press line to its full potential, we had to jettison the existing software and start from scratch.”

After in-depth studies, Unilin, Catael and Wemhöner joined forces to develop a completely new control system. “Wemhöner used the Siemens S5 and later S7 controllers. A fresh start meant we were able to completely redesign the software in Siemens TIA Portal,” Sammy continues. “As a Siemens Solution Partner, we knew we could open up a whole range of possibilities: unified naming, reusable components, object-oriented construction, tighter structure and libraries full of useful tools.”

Manageable in an exceptionally smooth manner

The team opted for an ISA-88 architecture to set up the system optimally. This divides the entire production process into hierarchical levels: from machine to zones, units and modules. “This creates a pyramid structure with step-controlled sequences,” Sammy explains. “This structured layout keeps the logic clear and makes the line much easier to manage.”

The combination of ISA-88 and TIA Portal offers a whole range of advantages: “Thanks to modularity, uniform naming and reusable components, multiple programmers can now work on the software at the same time. And we can make changes quickly without shutting down the whole line. The trace and analysis functions in TIA Portal also help us debug more smoothly, track processes and refine the software.”

World record in Wielsbeke: switching in 5.5 seconds

A crucial link in the development process was the LSimaHydTO for hydraulic presses technology library. Rens Esselens, account manager at Siemens, explains: “The Wemhöner press is a hydraulic system, but thanks to our library of tools and pre-configured functions, Catael can control the cylinders with the precision of servomotors. Catael was the very first to try and apply the library on such a large scale. Sammy even went to our experts in Germany to explore the possibilities together.”

“Thanks to the unique combination of standard building blocks from the Siemens library, the pressing machine now switches smoothly between speed and force control,” says Sammy. “This happens amazingly quickly: the target for the mechanical change was 10% faster than the intended target. This not only makes the revamped press line the fastest machine of its kind, but also reduces wear and increases precision.”

That precision translates directly into product quality – Unilin’s ultimate hobby horse. By the way, to monitor and control this quality closely, each panel passing through the press line receives a digital passport containing 2,400 process parameters – from pressure and temperature to speed.

Faster troubleshooting, more uptime

All press line operational data is also automatically collected, analysed and clearly visualised. This allows Unilin to adjust and optimise production continuously.

That visualisation is useful for the software team, and equally so for Unilin operators and technicians. Operators get real-time insight into all operational data via the intuitive interface. “During development, we kept in mind clarity and usability to make their lives easier,” Sammy explains. “The 400-plus screens all follow the same logical structure. We developed clear graphs with trends and provided automatic alarms. When an error message appears, the cause as well as a suggested action immediately appear. This saves minutes – and every minute counts in production.”

The system also offers comprehensive diagnostic functions for maintenance and troubleshooting. This enables preventive maintenance, increases uptime and prevents unplanned downtime.

Results that count

Thanks to updated software and visualisation, the Lux 21 press line in Wielsbeke impresses in all areas: efficiency, speed, flexibility and quality.

“The results are impressive,” says Henk. “The line now reaches a capacity of 15 million sq m of laminates per year, an increase of 25%. We can start up to 30% faster than previous lines, while better diagnostics mean less downtime and production changes run smoothly. This allows Unilin to respond flexibly to requests for specific types of laminate or a small batch. Quality is also more constant thanks to precision control and traceability. This also means less material loss and therefore less waste – and efficiency is energy gain anyway. This way, the Lux 21 line helps Unilin meet its sustainability targets.”

Meanwhile, the updated software is also running on the Press 5 line at Unilin North America in Thomasville, USA. The unified Siemens base ensured smooth, efficient rollout, training and maintenance.

“This project shows perfectly what co-creation can do,” Henk Capoen concludes. “Unilin challenges us, Wemhöner brings the machine expertise, Siemens provides the toolset and Catael connects everything into one high-performance, future-proof system.”