Mondi Inncoat GmbH
Mondi Inncoat?
Mondi Inncoat GmbH in Raubling has been a leading global supplier of high-quality silicone-coated release papers and films (so-called release liners) for over 60 years. The company relies on unique coating and process technologies, with sustainability playing a central role in its corporate strategy. The release liners produced impress with their outstanding flatness properties, dimensional stability and rigidity. Thanks to these optimal properties, Mondi Inncoat's release liners are used in a wide range of applications in advertising films, labels, adhesive tapes, for hygiene and medical applications and for sealants in the building materials industry.
As part of the listed Mondi Group, Mondi Inncoat is assigned to the "Functional Paper and Films" business area. The key to Mondi Inncoat's success lies in the team of around 280 employees at the Raubling (Germany) site.
Business Challenge
Challenge:
- High reject rate due to incorrect use of very similar or minimally different tools
- Time lost when searching for tools due to lack of transparency
- Tool mileage and wear are not recorded, making efficient maintenance more difficult
- Need for robust technology that works reliably even in demanding environments
Goals:
- Minimize production downtime and waste
- Improving transparency in the production process
- Scalability of the system to other locations and applications
Solution
- Process analysis and detailed examination of the production processes including the prevailing environment
- Implementation of a two-stage proof of concept (technological clarification and on-site integration)
- Technology selection and testing of the use of RFID tags under difficult conditions (alkaline environment, hazardous area)
- Concept for attaching RFID tags to tools, development of the Omlox standard for future expansion, integration of RFID tags in the production system and MES
- Implementation of the RFID tracking system for the unique identification of tools (e.g. printing rollers)
- Equipping tools with RFID tags, installing RFID readers at five production stations and at washing and storage stations
- Integration into existing systems (Siemens MES and PI system) via OPC UA interfaces
Services
- Consulting and planning of RFID integration.
- Implementation of a proof of concept (PoC) for technological clarification and integration.
- Development of prototypes for attaching the RFID tags.
- Technical tests to ensure signal quality, durability and mounting methods.
- on-site installation and commissioning of the system.
Technologies
- UHF RFID tags and RFID readers.
- OMLOX standard for possible extensions.
- Siemens MES, Osisoft PI system.
- OPC UA interfaces for data communication.
- Industrial PC for controlling the RFID readers.
Methods
- Implementation of a proof of concept in two phases: Technological clarification and on-site integration.
- Iterative testing of fastening methods (gluing, screwing, integration in sleeves or rollers).
- Simulation and optimization of RFID positioning to maximize read range and signal quality.
Value
- Reduction of production downtimes through early detection of incorrect tool assignments.
- Enabling traceability and avoiding incorrect material deliveries and the associated costs.
- Enabling predictive maintenance.
- Scalable solution for additional locations and production lines.
- Potential to expand the system (e.g. UWB for warehouse logistics).
