C-BEYOND and VibeTrack: Data-Based Efficiency in Compounding

Transparency and Efficiency with C-BEYOND

C-BEYOND connects extrusion systems and centrally provides all relevant operational and process data in the cloud. Important key performance indicators (KPIs) such as plant availability, production volume, product quality, and overall equipment effectiveness (OEE) can be evaluated in real-time and visualized in reliable, user-friendly analysis charts. Configurable alerts can be sent in real-time to operating personnel or production engineers to avoid scrap production or prevent plant downtimes.

Users have a transparent overview of the performance of individual extruders as well as entire production sites at all times. Furthermore, trends can be recognized early, production processes can be specifically optimized, and informed decisions can be made.

Another advantage of C-BEYOND is in improved production planning. Current information on production progress is available in real-time, allowing for efficient preparation of order changes and reduction of machine downtimes. Production interruptions due to recipe changes, maintenance tasks, or other operational downtimes are automatically recorded by C-BEYOND and can be supplemented with additional information by the operating personnel. The insights gained help identify the causes of downtimes and exploit long-term optimization potentials.

Sustainability through Data-Based Energy Transparency

With the Sustain App from C-BEYOND, energy consumption can be monitored in detail at the plant and component level. The platform captures the energy demand of extruders and relevant aggregates in real-time, thereby laying the foundation for targeted efficiency measures.

Based on energy consumption, CO₂ emissions per kilogram of product produced can also be determined. This provides companies with valuable information to support their sustainability goals, avoid energy waste, and utilize resources more effectively.

VibeTrack: Condition Monitoring for Maximum Plant Availability

Complementing C-BEYOND, the condition monitoring system VibeTrack expands the possibilities of digital plant monitoring. The system was specifically developed for ZSK twin screw extruders in sizes ZSK 40 to ZSK 140 and detects even the smallest changes in operating behavior before they lead to unplanned failures.

Sensors on the motor, gearbox, and process section continuously capture vibrations. Additionally, VibeTrack monitors the oil condition of the gearbox. When critical thresholds are reached, an automatic warning is issued.

Continuous condition monitoring enables proactive maintenance planning. Necessary service work can be scheduled in a timely manner before costly consequential damages or unplanned production interruptions occur. This increases plant availability and helps maintain productivity at a high level over the long term.
As part of a service agreement, our certified experts remotely access the measurement results and regularly create in-depth analyses of the plant's condition. If anomalies occur, we take immediate action, provide timely support, and offer clear recommendations for action.

Digital Services Throughout the Entire Plant Lifecycle

Together, C-BEYOND and VibeTrack form a powerful foundation for data-driven production and service processes. While C-BEYOND creates transparency over production performance, energy consumption, and process data, VibeTrack ensures continuous monitoring of machine condition.

By linking production, energy, and condition data, companies can operate their plants more efficiently, plan maintenance measures specifically, and support their sustainability goals.

Thus, Coperion's digital solutions accompany customers throughout the entire lifecycle of their plants – with the aim of sustainably increasing productivity, availability, and sustainability.