Italycs® 5

Blown Film Line Control Technology

Total Integrated Process Control

Reliable state-of-the-art hardware for a process control system designed and refined by multi-layer blown film specialists. A logical layout and flow that makes operating a line intuitive, allowing you to focus on starting and completing your customers’ orders with minimal wasted effort. The security of managed logins and a full year of timestamped process records, easily searched, trended, and reported.

It’s all in ITALYCS 5

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Italycs® 5

- Blown Film Line Control Technology

Total Integrated Process Control

Reliable state-of-the-art hardware for a process control system designed and refined by multi-layer blown film specialists. A logical layout and flow that makes operating a line intuitive, allowing you to focus on starting and completing your customers’ orders with minimal wasted effort. The security of managed logins and a full year of timestamped process records, easily searched, trended, and reported.

It’s all in ITALYCS 5

Robust Technology

Modern Design

Experience

Designed for Blown FIlm

Total Process Control

Logical, Easy to Operate

Full Traceability

Timestamped Records

Usability, total repeatable control, and functionality meet in the latest version of our line control system, ITALYCS® 5. Simple tensions, speeds, recipes, lay-on force, and more, are tailored to the exact specifications of your clients’ needs. Intuitive touchscreen application is fully configurable to support, delivering customizable quality control and line performance reports right into your hands.

Operate and control complex 11-layer lines, as simply as a 3-layer line, ITALYCS® 5 will allow you to monitor, control, and repeatably changeover all your vital process parameters, such as:

  • Extruder speed and motor load
  • Extruder and auger specific output
  • Barrel and melt pressure
  • Melt temperature
  • All temperature zones
  • Layer and total film gauge
  • Line speed and layflat
  • Blender recipesRepeatable changeover
  • Job completion
  • Trending quality
  • Security access
    Many other values

Robust Technology - Modern Design

ITALYCS 5 is built with current, widely-supported hardware and protocols, including:

Distributed IO over Ethernet/IP
– drive and device upgrades are easier to implement

Allen-Bradley ControlLogix PLC and Point IO

HMI runs on rugged industrial PC from Siemens (SIMATIC IPC547G)
– Intel processor Core i7-6700
– 2 x 1TB hard disk drives, cloned for back-up
– 16GB DDR4 SDRAM (2x 8GB) Dual Channel
– Lockable front door for authorized access to front swap media,
power, reset, USB interfaces, front fan and dust filter
– 64-bit Windows 10 operating system
– third-party software (e.g. gauge measurement) can be integrated

19” Siemens Industrial Touch Screen for all user inputs
– keyboard & mouse also included and fully supported

A suite of responsive HMI apps programmed in C#
– asynchronous screen updates for minimal display lag
– Microsoft SQL Server used to store parameter values, set-points,
history, etc
– licensed software fully supported by developers of the code

Main and Remote Stations are standard
– run or monitor the line either from the floor or from near the bubble, with full redundancy

 

Experience - Designed for Blown Film

ITALYCS® (Integrated Temperature And Layer Yield Control System) was first designed for blown film line control by blown film specialists in the 1980’s. Since then, continuous improvement of hardware and software combined with relentless focus on effective operation of multi-layer blown film lines have resulted in today’s Version 5.

Operate and control complex 11-layer lines, as easily as a monolayer line

  • Simple, logical menu driven interface
  • Remote operator station near the bubble for fine-tuning or trouble-shooting processThe Main Process Screen – Designed for the Blown Film Operator

Total Process Control - Logical, Easy to Operate

Usability, total repeatable control, and functionality meet in the latest version of our line control system,
ITALYCS® 5. All process settings are fully integrated to ensure easy and rapid start-up and process
monitoring. Intuitive touchscreen application allows the operator to operate and control complex 11-
layer lines, as easily as a monolayer line.

ITALYCS® 5 will allow you to monitor, control, and repeatably change over all your vital process parameters,
such as:

  • Line speed and output rate – change one and the other is automatically adjusted
  • Layflat width – IBC and bubble cage respond in sync
  • Layer ratios and total film gauge – adjusts extruder speeds as required
  • Monitor and trend key indicators of the process, such as
    – Barrel and melt pressures
    – Extruder speed and motor load
    – Melt temperature and all temperature control zones
    – Extruder and auger specific output
  • Save and recall full recipes including blender recipes for repeatable changeover
  • Managed security access
  • Job completion management

Full Traceability - Timestamped Data Records

ITALYCS 5 is designed to keep a detailed record of what happened, when. Why did the line stop at 2AM?
Look in the history to find out if a pull cord was accidentally tripped, or a loader ran empty. How long did
it take for someone to respond? Alarm History tells the story.

Microsoft SQL Server is used to store alarms, process values, setpoints and more for one year. The built-in
Trending app allows graphical display of up to 10 tracked parameters – setpoints, actual values, deviations
and variations. Zoom in or pan across timescale.

Any ITALYCS® screen including Trending can be printed, saved as an image (XPS), or output to a CSV file.
Up to four standard reports are available to make your routine reporting easier:

Alarm History
Roll Report
Resin Usage Report
Product Report

Fully configurable security with timestamped logins and individual passwords allows you to control access
to sensitive screens like calibrations.