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W A T L O WTemperatureControllersCase HistoryWatlow’s PPC-2000Controller ProvidesImmediate Benefits toLarge User Blown-Film PlantProblem:Pliant, one of the world’s largestblown film facilities, was looking toupgrade their controller technology.Their South Deerfield, MA locationoperates blown mono and coex filmlines producing film and packagingproducts for personal care, medical,food industrial and agriculturalmarkets. Two of their three-layerlines, which had five heat/cool zonesper extruder barrel and over 30temperature control zones overall,were controlled by an older analogunit that gave no insight into theprocess. With no means to monitorcontroller performance and frequentdowntime, Pliant decided to improvetheir system.Solution:This Pliant facility worked with a localauthorized Watlow distributor whoalso had control system integrationcapabilities to develop a solution.This partner was instrumental inimplementing a customized and<strong>com</strong>plete system solution based onthe PPC-2000 controller.Watlow’s PPC-2000 provided apowerful and cost-effectiveapproach for their applicationswhere other controllers wereawkward, time-consuming and didnot adequately control the process.The PPC-2000 <strong>com</strong>bined easy tosetup multi-loop process control andprogrammable logic control in one<strong>com</strong>plete package. The controlleralso offered them a very userfriendlyalternative to strategiesemploying PLCs with discretecontrols.The integration incorporated a thirdparty touch screen with Watlow’smenu-driven, customizable ANAWINHMI software to provide Pliant withdata logging, graphing capability,auto-tuning, recipe managementand built-in alarm handling features.The modularized design of the PPC-2000 also allowed it to grow withPliant’s system. Various analog anddigital I/O modules plus controlloops could now be centralized intoone <strong>com</strong>pact unit and programmedas an integrated system.Pliant was able to speed time tomarket with their customized PPC-2000 and the benefits were realized<strong>com</strong>pany-wide:• Machine operators were able togive direct input into how tocustomize the control system• Managers and supervisors wereable to use remote screens tomonitor the line, collect and viewhistorical data to identify trendsand make adjustments• Management benefits includedreduced downtime, lower powercosts, the ability to optimize resinusage and repeatable productionrunsThe robustness, ease of use andexpandability of the PPC-2000<strong>com</strong>bined to make Pliant’sproduction more efficient and costeffective. Due to this success, futureplans called for retrofitting otherblown film line controllers with thePPC-2000 controller.ExtrusionTemperature Controllers277