Sabond - Belgian quality panel for Chinese machine

Plastigi, a specialist in rotational moulding, had a machine built in China. Upon installation, it became apparent that the cabinets for powering the moulds and control did not comply with Belgian standards. Installer Sabond brought in Breemes for advice and the design of a low-voltage panel that did comply.

"With their knowledge and commitment, we were able to successfully complete the power section of the mould heating."

 

Plastigi in Herentals (B) specializes in the rotational molding of high-quality plastic products. In this process, plastic powder is heated in a rotating mold, so that it melts evenly against the wall and forms a hollow product. The products are supplied, among others, to sister company Valiente, which supplies champagne coolers and flower pots in exclusive designs. Traditionally, the molds are brought to the correct temperature using heating oil or gas. Plastigi has chosen sustainability and is now a pioneer with ‘zero emission’; the molds are electrically heated using ‘green’ electricity. This requires substantial power, so a reliable and safe power supply is crucial. At the same time, this sector is also facing price pressure. This prompted Plastigi to develop a rotational molding machine together with a Chinese machine builder.

Power supply and energy distribution

The mold heating became part of a complete robotic installation. Electrical installer Sabond was brought in for the power supply and electrical connection, explains managing director Bert Aerts. Sabond (Service Aerts Bert ONDerhoud) in Tessenderlo (B) was mainly active in the food industry and has expanded into other industries in recent years. “So last November, we were approached by Plastigi. We had to take responsibility for controlling the heating of the molds; ensuring the power supply and distributing the energy to the right locations. The problem Plastigi encountered was that the Chinese machine, with its control and power cabinet, did not comply with Belgian standards and some optimizations were required. They asked us to make a proposal on how to resolve this.”

“The Chinese machine, with control and power cabinet, did not comply with Belgian standards and some optimizations needed to be made”

Bert called on Breemes, in the person of electrical engineering consultant Gert Vanwezemael. “They are our partner for the supply of electrical components and support in that area. So I went with Gert to the site to see how we could bring the power, 500 amps, to the machine. The question was how we could properly distribute that power in the cabinets according to Belgian standards and how we could equip them with the necessary protection devices. “There were European-approved components on the panels, but there was no way the entire device complied with the European standard. So it was important to consider how we could obtain approval from the inspection body – perhaps by replacing some items with components that are accepted here in terms of standards.”

Short-term solution

It turned out that modifying one cabinet was practically unfeasible, Aerts reports. “So we chose to build a new cabinet for the energy distribution, while we modified the other cabinet and put it into use temporarily. It still contains a power switch from a European brand that complies with Chinese standards. We will probably still have to replace it if we want to get everything technically approved.” Vanwezemael got to work on the new cabinet. “Based on the required power, voltage and current, I carried out a complete low-voltage study. This included short-circuit and cable cross-section calculations and configuration of a low-voltage panel in Sivacon S4 from Siemens. Naturally, I based this on the standards that are applicable here. After discussing and modifying my design, we supplied Sabond's order and I went to supervise them during the assembly of the panels.&rdquo

“The customer is satisfied with it”

Meanwhile, the installation at Plastigi for one part of the machine is almost complete, and that is quite fast after the initial inquiry came in November, Vanwezemael feels. “We are now at the beginning of March, and Bert has managed to get everything properly installed and almost ready for use in a relatively short time.” A lot of energy has gone into getting it working on time, Bert confirms. “It wasn't a matter of plugging it in and having everything start running. A number of issues came to light and we had to resolve them. Approval for the quotation came at the beginning of December, and we had the mechanical assembly completed by the beginning of January. Gert really had to push hard to meet the delivery times for the materials, and we simply continued working between Christmas and New Year's. The result speaks for itself; the customer is satisfied.” The inspection still has to take place, but Aerts and Vanwezemael are fully confident about that.

A great deal of support

In any case, the experience was positive in terms of the cooperation with Breemes and the ease of use of the Siemens Sivacon S4 cabinets in combination with the Siemens switchgear, Aerts says in conclusion. “During the assembly, a few gaps came to light that we had not taken into account. At one point, Gert himself drove around to get the required materials to the right place. Breemes really put a tremendous amount of energy into it. That is one of the reasons why we work with them; with their knowledge and commitment, they enable us to bring a project like this to a successful conclusion. If we had all had to figure it out ourselves in order to get those materials on time, it would have cost us a lot. We received a great deal of support from Gert here. The project is not finished yet, but I am already working with him on another project.”

  

  

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