KELLER IMS process and automation engineering - The continuous automation concept from the operational – to the management level

Plant network system

Programming server

• Central server for all PLC projects.
• Ethernet allows access to all connected PLC systems.
• Centralised storage of PLC software and backups make sure that all users can access the current projects at any time.

Teleservice

• Worldwide remote diagnostics during commissioning or troubleshooting carried out by system experts in Ibbenbüren-Laggenbeck.
• Remote maintenance performed by the customer's staff during weekends or holidays.
• The options include process computer operation, PLC programming, data transfer, video and audio transmission.
• Secure connection through VPN/firewall via the systems infrastructure provided by KELLER IMS.

Data backup and storage

• Complete data backup of process computers, PLC sources and automatic safety storage buffers from PLC to the central server.
• History files are backed up at multiple levels. Direct recovery of data or complete system structures on the clients systems.

Wi-Fi network

• A Wi-Fi network allows wireless programming, troubleshooting and maintenance in the factory.
• Mobile services with notebook, tablets or handhelds.

Process control & maintenance

Alarm management system

• Operating and fault messages are texted to a defined number of configured users.
• Supports message selection, preparation of escalation charts, shift tables, acknowledging of messages, etc.

Maintenance manager

• Configuration, monitoring and logging of maintenance jobs.
• Automatic activation of maintenance procedures after time, incident, cycles, etc.
• Structured data according to machine, plant, factory, etc.
• Storage of maintenance files.

Datamanager

• Operational data acquisition for various industries.
• Acquisition of consumptions, consumables, etc.
• Acquisition of production volumes, production times, counter readings.
• Overview of current production by target/actual performance comparison.
• Preparation of shift-depending production reports and measuring protocols.
• Recording and filing of collected data.

Energy management system

Central system for collecting amounts of energy in various industries. Subdivision of the complete plant into different measurement areas. Each area is equipped with different meters (current, water, gas, etc.). Integrated computing functions can carry out any number of calculations. Alarm monitoring of counts and threshold monitoring of counter values. Analyses over any review period or as a continuous measurement in the form of graphs or Sankey diagrams. Spatial representation of the counters/measurement spots on installation graphs. Integrated data interface to other K-matic process control systems. Functions to export the analysis data to Microsoft Excel©.

K-matic 4.0

Industry 4.0 links the production with the most modern information and communication technology. Evolutionary development of machine software through the use of Internet technology opens up new ways in the production of heavy clay products. The focus here is on the intelligent, horizontal and vertical interconnection of people, machines, objects and information technologies in real-time for a dynamic management and an optimisation of complex systems. Smooth communication from the sensor to the Internet is a prerequisite for industry 4.0. In the Industry 4.0 factory intelligent machines coordinate manufacturing processes autonomously, handling robots cooperate intelligently with people and transport vehicles perform logistics tasks on their own.

After Sales Service

Production without breakdowns. Actually, even reliable and low-maintenance machinery and plants of the KELLER Division need their regular maintenance service. It has been proven that preventive inspections and planned repairs are more cost-effective than unexpected machine downtimes. The KELLER Division relies on its efficient service team that promises to establish a true partnership with you. We offer you a customer service that is adapted to all the different life cycles of your plant. On a worldwide scale.

• 24 hours emergency service.
• Customer care on site in your native language.
• Professional spare parts management.
• Continuous support for your installed plant to optimise your production whenever needed.
• Comprehensive training for your operating staff.
• Easily understandable plant-specific technical documentation.

Exemplary reference project for environmental protection and sustainability

KELLER IMS equips tunnel kiln for climate-friendly use of landfill gas as an energy source  

Already in 2010, KELLER IMS in Ibbenbüren-Laggenbeck, together with its French mother company Legris Industries, embarked on their sustainability project. The spirit and purpose of this project is to raise and strengthen the awareness of the whole group of companies for an environmentally-conscious and sustainable behaviour in all its activities. In accordance with this new company guideline, all corporate activities shall be guided by the principle that environmental considerations rank equally with social and economical aspects. 

How this concept of sustainability can be put into practice and serve as a precedent is demonstrated by KELLER IMS with its current reference project for a kiln modification in an Australian brick plant.

In 2012, the Australian brick manufacturer Austral Brick in Sydney inquired for the first time about the possibility to use landfill gas to heat a tunnel kiln. The old clay pits owned by Austral Bricks were filled with waste during the past years. The landfill gas had to be flared off without recovering its energy. The brick manufacturer Austral Bricks and the landfill site operator Veolia took concerted action to push forward a wise use of the landfill gas. They soon choose KELLER IMS as an appropriate partner to create a technical solution and to carry out its implementation.

For this purpose, KELLER IMS developed a landfill gas blower station that provides the necessary primary pressure for the burner groups of the tunnel kiln and removes the moisture from the landfill gas. Moreover, KELLER IMS converted four burner groups to dual gas burner groups. These four burner groups now enable combustion of 225 m³/h landfill gas with approx. 5.6 KWh/m³N each. Due to this conversion, Austral Brick is now free to choose beween conventional natural gas and landfill gas as their energy resource. After only three weeks' time, the conversion was completed in November last year and the new, environment-friendly plant was set to work. At present already three of the four burner groups are permanently operated with landfill gas. The launch of the fourth burner group will be made very soon. Should the earnings forecasts for the landfill gas be fulfilled, further burner groups will be converted to environment-friendly dual operation. All persons involved were very happy about the excellent cooperation in terms of environmental protection. The plant is a "win-win" for everyone. Due to the rational use of the landfill gas, the CO2 emission will be reduced by at least 3,500 tonnes per year.

Landfill gas:

Landfill gas is a flammable gas produced in landfills when organic substances degrade. Due to its high methane content, landfill gas is very harmful to the climate when it is released into the atmosphere. Uncontrolled landfills therefore take a leading position amongst the climate-damaging methane producers. Landfill operators are required to capture and to neutralise developing landfill gas. Ideally, landfill gas can be used to produce energy. The specific calorific value of landfill gas is at least about half of that of natural gas.