Smart Polyphenol manufacturing Supervisor
BEinCPPS Business Experiments in Cyber Physical Production Systems
HORIZON 2020 – project 680633
Open Call 2
The overall aim of the project is the experimentation of an innovative supervisor system on a polyphenolic extraction plant to reach two competitive goals, such as:
removal of production defects (Zero-Defect Manufacturing): finished product characteristics remain within the strict limits imposed by quality control and the quantity of product discarded for non-compliance is reduced to a minimum;
energy efficiency of the plant: the production chain is optimized to reduce energy consumption while ensuring a compliant production.
The particularity of the process did not allow the achievement of these objectives with a standard supervision system. This is because the compliance range is very tight, and the chemical/physical characteristics of the finished product are heavily influenced by environmental factors (temperature, humidity, lighting, etc.), the characteristics of the raw material and the processing time.
Plant working scheme in the prevoius configuration
Plant working scheme after SPS installation
Idea75 has developed SPS (Smart Polyphenol manufacturing Supervisor).
By combining CPS and IoT technologies, SPS implements a Decision Support System (DSS) on the production line of polyphenolic extracts at Poli4Life's production plant.
SPS consists of an advanced system for forecasting and evaluating the quality of the product. This system monitors the production process, detects defects and deviations from the conformity range of the finished product, and reacts with the automatic adjustment of machine settings.
SPS retrieves information from the production line to provide suggestions to the operators on the actions to be taken to improve the quality and the energy efficiency of the process, based on historical data and KPIs.
SPS is based on a 3-level architecture completely compliant with BEinCPPS standards:
Field: consists of sensors, actuators and a gateaway (SPS-gw) for data acquisition from the field and actuations management;
Factory: middleware for managing the communications between the field and the cloud system;
Cloud: guarantees storage, data processing and the user interface.
Smart Polyphenol manufacturing Supervisor enabled:
20% reduction in the waste rate of non-conforming finished product;
10% reduction in global energy consumptions of the producte line.
15% improvement in the mean quality of finished products.
Poli4Life - Terni (TR, Italy)
Reduction of the waste rate of non-conforming finished product before and after SPS application
Energy consumption comparison: before and after SPS application
stakeholders & Credits
Giuseppe Leonardo Cascella, PhD
MSc with honors and PhD in Electrical Eng. @Politecnico di Bari (IT)
EU Marie Curie Fellow @Nottingham University (UK)
40+ international papers
30+ industrial and R&D projects
Antonio Sacchetti, MSc
MSc in Electronic Eng. @Politecnico di Bari (IT)
MBA @SPEGEA Business School
CEO @Tera srl (winner of the Seal of Excellence - Horizon 2020's SME)
Author of 3 italian and 2 international patents,
2 community designs and 1 copyright
40+ industrial and R&D projects