Visualization and control of energy consumption at Toray Textiles Central Europe

December 19, 2022 | Reliance SCADA

Toray Industries is a global leader in the manufacture of waterless offset printing plates. Established in 1926, the company has a global presence with factories and sales offices primarily in Asia, Europe, and the Americas. The company's main products are fibers and textiles, plastics and chemicals, information-, engineering-, and the environment-related products, and carbon-fiber composite materials.

The company's Czech branch (Toray Textiles Central Europe, graphics division IMPRIMA), which is headquartered in the city of Prostejov, is equipped with a state-of-the-art line for the manufacture of waterless plates.

Control system

The system consists of a Siemens SIMATIC S7-1200 central control unit and the Reliance SCADA/HMI system (Reliance 4 Control Server).

The control system is responsible for:

  • Monitoring of the manufacturing facility's consumption of active and reactive energy
  • Monitoring of the current active and reactive power output including the power factor
  • Monitoring of load-shedding data
  • Providing notification via an alarm and a text message when exceeding the set limits
  • Logging the process data to an SQL database

An application registered as a Windows service and operated by Reliance 4 Control Server runs continuously on the company server. Client versions of the program (Reliance 4 Control) run on computers connected to the company's intranet.

The application is used to monitor and optimize power consumption at Toray's manufacturing facility. Above all, it includes monitoring load-shedding data with the possibility for the operator to set limits and to be notified of them being exceeded via an alarm or a text message. Active and reactive consumption values for the past 15 minutes, hour, day, or month are stored in the SQL database on the server. The application can display this data in a table or using a custom report. It can also be filtered and exported to an Excel file.

In the future, the system can be expanded to include energy consumption control by automatically switching off some appliances.

Examples of visualization windows

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Toray Textiles Central Europe, aerial view

Jan Tandler