Smart moulds intelligente Formen

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2 Positioning Factory Automation Enterprise Layer SOLVE IT! Control Layer I/O-Layer BUS IT! Connectivity Layer CONNECT IT! Sensor Layer SENSE IT! 2

3 What is an intelligent chocolate mould? Data can be written into the mould and read out again The environmental conditions don t influence the data storage and exchange They meet all the requirements that are demanded from conventional moulds 3

4 What are the components of a RFID-aystem? Field bus (e.g. Profibus, DeviceNet, Profinet, Ethernet, etc) Interface IP67 Read-Write- Head Data carrier contact-free information exchange 4

5 Identification of chocolate moulds Data carrier TW-R16- compact form factor chemically resistant vibration and temperature resistant food conform material according to FDA passive function without battery according to ISO

6 Identification of chocolate moulds Read-write heads in M30 threaded barrel housing mould identification during production wash-down version high quality materials high chemical resistance food contact materials (FDA) protection class IP69K Read-write heads in Q80L400 housing mould identification at the washing machine reliable identification of moulds in different sizes 6

7 Which data are stored where? ERP write and read 7 number of cleaning cycles number of production cycles produced amount [kg/mould] life span of the mould [days] article number product name number of mould date of production depositing program cleaning program Agathon 11111/0 100g bar 267/ Solid 100g Hildebrand 4

8 Which data are stored where? Proposal of the working group all data ERP data base write once read repeatedly number of cleaning cycles number of production cycles produced amount [kg/mould] life span of the mould [days] article number product name number of mould date of production depositing program cleaning program Agathon 11111/0 100g bar 267/ Solid 100g Hildebrand 4 unchangeable data 8

9 RFID in chocolate production Insertion into the production line Depositing of chocolate Detecting residues of chocolate 9

10 RFID in mould cleaning Insertion into the washing machine Identification of the mould 10

11 RFID in mould logistics Standard mould containers effective mould logistics suitable for high-bay warehouses RFID at the mould container simplified storage and retrieval complete transparency by linking the data of the mould container with the data of individual moulds store location and mould data in the ERP system additional data carrier on the mould container 11

12 RFID in mould logistics Das Bild kann nicht angezeigt werden. Dieser Computer verfügt möglicherweise über zu wenig Arbeitsspeicher, um das Bild zu öffnen, oder das Bild ist beschädigt. Starten Sie den Computer neu, und öffnen Sie dann erneut die Datei. Wenn weiterhin das rote x angezeigt wird, müssen Sie das Bild möglicherweise löschen und dann erneut einfügen. Identification of mould containers Control of internal logistics 12

13 Benefits for chocolate production More flexibility and efficiency automatic selection of the production program the mould controls the processes dosing demoulding intensity less down time goal: mono-line performance for flexible lines better documentation of the shift efficiency 13

14 Benefits for chocolate production Better control of product quality and product safety identification of the mold before the depositing process compatibility check identification and tracking of falsely or incompletely filled moulds removal of moulds with repeated production problems control of hygienic standards for each mould tracking and removal of damaged moulds acquisition and processing of mould related process data Improved traceability 14

15 Benefits for mold cleaning More flexibility and efficiency optimal use of cleaning agents, water and energy higher life span of moulds by reduction of the use of detergents better documentation of the shift efficiency Better control of product quality and product safety avoid cleaning residues on the mould prevent loss of mould gloss because of surface abrasion reduced risk of mold fracture Improved traceability 15

16 Benefits for mould storage Mould management pre-calculation of the expected mould life span mould selection before a fracture occurs permanent inventory of the stock of moulds Save the mould data on the mould container determine the storage location of moulds pre-condition for a fully automated production of chocolate 16

17 Outlook Combination of RFID with sensor functions Acquisition of additional mould properties and link with the mould database 17

18 Thank you for your attention! Dr. Bernhard Grimm Diplom-Physcist Vertical Sales Manager Food and Packaging Industry phone: