Wireless technology helps Sun Chemical improve ink quality

  • December 07, 2009
  • Emerson Automation Solutions
  • Case Study
December 7, 2009 — Emerson Process Management’s Smart Wireless technology is helping Sun Chemical improve ink quality and collect additional data in compliance with its air permit classification at its Kankakee, Ill., facility. The world’s largest producer of printing inks and pigments is using Emerson’s Rosemount wireless DP transmitters and a Smart Wireless Gateway to deliver reliable, continuous process data from two applications to its PLC.In the first application, the devices measure differential pressure on filter housings used in ink production. The pressure changes as the filters become clogged with particles. Alarms sent to operators signal when filters should be changed. Periodic staff rounds to check gauges on the filter housing and record the data manually are no longer necessary.“Now we can ensure that we don’t over-pressurize the filter housing, and that we provide better quality ink to our customers,” said John Dwyer, Sun Chemical process engineer. “We have saved thousands of dollars in eliminating material rejects.”The second application enabled Sun Chemical to be compliant with a modified air permit classification by quickly establishing a cost-effective monitoring network to measure vapor stream from solvent vent condensers at multiple locations on roofs across the facility. Running conduit for a wired network would have been physically difficult and more expensive. “With these points spanning the entire site, the multiple roof elevations, and special electrical classifications, a wired solution would have been a challenge,” Dwyer said. “Emerson’s ‘peer to peer’ communication between the wireless instruments gave us a robust solution. In fact, as we add instruments, the network becomes more secure and reliable.”Sun Chemical easily installed the Smart Wireless technology and Emerson helped to integrate the network with the company’s PLC. The self-organizing network has been operating without problem since commissioning.“Now that the network is established and more monitoring points are available, the plant can fulfill its desire to pick up more process monitoring data and do it fairly easily,” Dwyer said.In addition to the Smart Wireless solutions already installed at Sun Chemical, Emerson offers a wide range of wireless field instrumentation and plant operations equipment, including Fisher position monitors, Rosemount analytical and Machinery Health Management devices, and native wireless interfaces to AMS Suite predictive maintenance software, DeltaV or Ovation digital automation systems, and SmartStart services.About Emerson Process ManagementEmerson Process Management, an Emerson business, is a leader in helping businesses automate their production, processing and distribution in the chemical, oil and gas, refining, pulp and paper, power, water and wastewater treatment, mining and metals, food and beverage, life sciences and other industries. The company combines superior products and technology with industry-specific engineering, consulting, project management and maintenance services. Its brands include PlantWeb, Syncade, DeltaV, Fisher, Micro Motion, Rosemount, Daniel, Ovation, and AMS Suite.About Emerson Emerson (NYSE:EMR), based in St. Louis, Missouri (USA), is a global leader in bringing technology and engineering together to provide innovative solutions to customers through its network power, process management, industrial automation, climate technologies, and appliance and tools businesses. Emerson’s sales in fiscal 2009 were $20.9 billion. The company is ranked 94th on the Fortune 500 list of America’s largest companies. Learn More

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