The data can be easily accessed using the new Monforts Smart Support and Smart Check apps for an instantaneous status overview.

All specifications relating to machine performance and the production process can be mapped, to enable vastly simplified and targeted analysis for controlled planning and production. Insights harnessed from such analysis can be used to optimise the actual production process.

At the same time, potential sources of error can be anticipated and eliminated, enabling improved machine availability while considerably minimising downtime.

Parts prediction

In addition, the digital twin system provides information on the individual wear parts of a system, such as, for example, converters or gears.

“Operators and mill managers are informed by Smart Check sensors when maintenance or the replacement of key components will be required, well ahead of time,” explains Monforts Vice President Klaus A. Heinrichs. “Direct access to the integrated Monforts webshop allows users to instantly order such parts when they are needed, virtually preventing machine downtime.”

On request, Monforts can also virtually monitor machine performance and pro-actively alert customers to the need for preventative action. In such cases, however, data is only ever called from the cloud by Monforts when customers have given their full consent, in the interests of data security.

Data from Smart Check, for example, can even be used to analyse a system’s energy requirements, allowing machine operation to be optimised by tailoring production runs to the peaks and troughs of electricity costs.

Remote maintenance assistance

At present with Smart Support, customers can also contact Monforts service via smartphone or tablet, in order to access support on site via a remote visual link. Monforts service specialists can point out individual system parts on the customer’s smartphone and assist them in troubleshooting. Documents such as machine documentation can also be shown in real-time via white-board over a smartphone, tablet or office PC. 

“The Monforts digital twin system and apps are being made available for all of our machine ranges going forward and will make the operations of our customers considerably smarter, and at the same time, simpler,” Mr Heinrichs concludes.

Further benefits and savings with the new Monforts MonforClean

Furthermore, Monforts will be presenting an energy-optimised new version of its industry-leading Montex stenter for the first time.

With the introduction of the new MonforClean exhaust air treatment system and other unique process innovations, Monforts has been able to further reduce the energy consumption of Montex stenters by a further 13%. Exhaust air treatment on stenter frames has posed particular challenges over the years, since the air can contain significant amounts of oil, fibre and even wax particles that may see emissions limits being reached in the processing of certain fabrics, depending on the legal specifications.

In addressing this issue, Monforts is now incorporating the MonforClean module into the stenter frame, so there is no additional space requirement. At the same time, the costs for laborious secondary installations and the piping of the exhaust air treatment components, as well as supporting structures are eliminated due to the machine configuration.

The waste heat from the drying process is used to pre-heat the drying air, resulting in a radical reduction in the conventional heat supply required compared to gas and thermal oil heating. The further integration of an automatic exhaust air filter washing system automatically cleans the module elements, ensuring the consistent efficiency of both the filter and heat recovery modules.

The modular MonforClean system is also available in different expansion stages and automates the heat recovery and exhaust air treatment, while eliminating odours and ensuring the exhaust air is highly purified before escaping into the atmosphere. 

This allows finishing mills to always be on the safe side, ensuring growing future demands in respect of heat recovery, exhaust air cleaning and odour elimination can always be met when required.