Complete Machine Control Retrofit
Available on all makes and models of molding machines.
Why Consider a B&R Control Retrofit from CPT?
Our B&R Control Retrofit package provides molders with a very cost competitive solution to improved machine and processing control without the cost of total machine replacement. Our control retrofits can upgrade your older molding machines to greater productivity, process control, flexibility, networking, uptime reliability and maintenance ease. With over a century of experience in the plastics industry, CPT’s team combines application engineering, processing expertise, practical operating experience and professional service installation for an all-inclusive approach to providing you the best control package at a great value.
What are the financial advantages of a Control Retrofit?
All of CPT’s retrofit packages are “ROI-Calculator-Created” and will provide substantial savings based on increased production and reduced scrap. Consult us for a personalized projection of return on investment for your application.
The following savings calculations and justification may not totally reflect your exact situation or costs but can be used as a guide to realize potential savings.
| Potential Financial Benefits from Replacing an Older Obsolete Control with a B&R Control Retrofit from CPT | SAVINGS |
| Typical repair cost for obsolete control components (based on 2 component repairs per year) | $3,000 |
| Downtime associated with component failure (based on 2 downtime occurrences for 5 days at $30/hr cost) | $7,200 |
| Scrap reduction due to better accuracy and improved repeatability (based on 1% improvement in scrap reduction at $30/hr cost) | $1,800 |
| Energy savings for auto shut-down when machine is at idle (based on 10% idle savings of 10KW at $0.08 per KWH) | $480 |
| Increased production for auto barrel heat start-up (based on one hour gained for 50 weeks at $30/hr) | $1,500 |
| Reduce downtime with improved machine and remote diagnostics (based on a 1% decrease in downtime at $30/hr) |
$1,800 |
| Additional machine options included with control (based on robot, air & core software, plotting, process monitoring etc.) | $3,000 |
| Reduce mold repair costs (based on saving 3 days of downtime for mold repair at $30/hr) | $2,160 |
| Increased machine utilization due to modern user friendly control (based on 1% increase in utilization at $30/hr) | $1,800 |
| Reduced cycle time due to improved clamp control and core sequence (based on 2% increase in production due to reduced cycle time) | $3,600 |
Total savings based on 6,000 hrs/yr and $30/hr lost revenue cost |
$26,340 |
Typical B&R Control Retrofit components
B&R Control Retrofit typical Features
- Fully flexible, programmable, configurable and adaptable to meet customer specific requirements for flexibility and function.
- Control Solutions available for injection molding, blow molding, structural foam molding and systems requiring automation.
- Ergonomic operator panel and HMI interface options.
- Proven technology for control loops and auto-tuning procedures allows high performance and precision.
- Modular construction for system communication and down stream integration via open bus architecture and standard components.
- Optimal support through intuitive and remote diagnostic functions, open interfaces and worldwide availability of components.
Software Features
- Position-based clamp control
- Closed loop control for injection velocity and pressures
- Five injection velocity segments
- Five pack and five hold pressure segments
- Core pull and core set software (A1-A5, B1-B5)
- PID temperature control all zones and nozzle with auto tuning
- Cold start screw protection with on/off override and soak timer
- Auto heat start-up and shut down
- Multiple levels of password protection and Operator Change Log
- Trending/plotting of temperatures, pressures and axis positions
- Recipe storage for mold data locally (40) or to USB device
- Alarm log and Alarm History of last 200 alarms
- Screen capture and save to USB device
- Process monitor and alarms
- Machine diagnostics of analog and digital I/O
- English/Metric selection and Multiple languages
- Sprue break timer and sequence
- SPC available option
- Robot interface software (SPI 3.0)
B&R is renowned for providing machine automation and process control solutions to global plastics, packaging, printing and paper, textiles, automobile, food and beverages, semiconductors, wood, metal and mining, pharmaceuticals and chemical manufacturers.
