As a service provider specializing in machine modernization and factory digitalization, we are here to increase the competitiveness of your business. With our advanced technology and innovative solutions, you can increase the productivity of your business and reduce costs. By modernizing your machinery park, you can renew your old and dysfunctional equipment with current technology. By moving your factory into the digital age, you can increase efficiency and optimize your production processes. We are committed to providing you with the most appropriate service with our company, our experience in the sector, our expert team and customized solutions. We are here to meet the needs of your business with our customer satisfaction-oriented approach. Contact us to get more information about our solutions for your needs and for collaboration. We will get back to you as soon as possible.

Why We Are Different?

01.

Quality

We only prefer long-tested, proven quality equipment.

02.

Innovation

We apply the most up-to-date measurement and control techniques in our industry.

03.

Compatibility

We prefer expandable systems for additional upgrade and development scenarios.

04.

Security

We prefer products with the highest operator and hardware safety.

Machine Modernization

Today, the extrusion manufacturing industry and film/sheet processing industry is a very competitive field with very narrow tolerances in product and service quality in terms of market structure. Production lines, without exception, have certain indispensable equipment in order to be competitive in terms of quality and efficiency. These equipment can be considered as separate equipment and units that work synchronously with each other from raw material entry to finished product exit. This equipment can be controlled by separate control systems independent of each other or by a central control system where all alarms and warnings are monitored. Malfunctions in electronic control systems, especially in lines over a certain age whose technology is behind, create major problems in production quality and performance. Erkinel provides solutions for control systems in all extrusion production lines, including such problematic lines. We renew the necessary mechanical equipment with current technology, while doing this, we prefer proven equipment from companies that are experts in the sector. We prepare the central control electronics and software in-house. Regardless of the age, brand or model of your machine, we provide complete modernization with guarantee.

Reduces operating costs

With renewed control technology, we reduce energy consumption, faulty production and machine downtime.

Extends line life

We extend the life of the line by replacing outdated and maintenance-free equipment with up-to-date versions.

Increases production efficiency

We increase total production with functional hardware upgrade options and the addition of necessary additional hardware.

Increases traceability

We upgrade your line's technology to an industry 4.0 ready level and ensure that all desired parameters can be monitored.

How Does the Process Work?

Preliminary interview

It is a meeting to discuss the insights about your in-sevice or out-of-service line. The meeting is mostly done online. Key data/information about the status of the line is examined and the situation regarding its potential is discussed. In case of sharing the field photos and visuals related to the line, a great foresight about the project cost can be created at this stage.

Field inspection

After the foresight proposal is found to be positive, a field investigation is carried out by moving to the next stage. If the technical personnel within the company will also take part in the modernization project within the scope of modernization, the first meeting with the relevant personnel is held during the field inspection process.

Project planning and final proposal

With the site inspection, the exact need for mechanical modification and new equipment is determined. Project cost and time planning are made together with the identified needs. Depending on the supply process, the production plan of the machine control equipment is made. If the line is in operation, a stop and mechanical modification planning is made. This is the stage where the official proposal is submitted with time planning and the project objectives are determined.

Supply and production

With the project approval and prepayment, the supply and production process begins. All control hardware is made ready for assembly in the field. All mechanical material production and supply is done at this stage.

Installation and commissioning

When it comes to the standstill stage, field studies begin depending on the need for planning and modernization. The control equipment prepared and the equipment determined within the scope of mechanical modification are transported to the field at this stage. After the installation, it is confirmed that the project targets determined during the project phase have been achieved. The project is completed by providing the technical and production personnel with the necessary training on production and maintenance.

Warranty process and after-sales services

The hardware used for modernization is guaranteed for 1 year. During the warranty period, technical support is provided in the form of remote connection or site visit in case of malfunctions. We have various technical support options for cases where the warranty period has expired.

Frequently Asked Questions

What exactly is the scope of modernization?

It covers mainly electronic power and control equipment and, where necessary, partial mechanical overhaul. The general application proceeds as disassembling all parts of the machine, renewing the paint, assembling the revised mechanical parts, and then installing the renewed power and control equipment.

What are the warranty scope and conditions after modernization?

The parts renewed in the machine are under warranty for 1 year after commissioning. The problems that may occur due to the working environment of the products in the field may cause them to be out of warranty. Get detailed information.

What are the technical support and service conditions after modernization?

1 year after commissioning, technical support and fault tracking in the form of telephone and remote connection to the machine is free of charge. In the following years, a technical support agreement is made upon request. Paid spare parts support is available out of warranty.

What are the responsibilities of our company during the project process?

During the field installation, our company acts as a supervisor, so field support personnel are expected to be met by you. In cases where qualified personnel cannot be assigned by your company in the field, the labor at this point is charged separately by us.

Is there an age limit for modernization?

There is no age limit. Any line whose mechanical part works correctly can be modernized.

Are there any brand and model restrictions on the modernized machine?

There is no any brand model restriction. Project feasibility is made by taking into account the costs of mechanical parts.

My line is operational, how much line downtime will I experience during the modernization process?

The overall stance becomes clear only when the size and scope of the project is determined. The project plan is made to keep this downtime to a minimum. The entire procurement and preparation process is completed before the hearing begins. Depending on the size of the project, it can cover a period of 4-8 weeks.

Will my line efficiency increase after modernization?

Preventing surprise stops on the line, entering the new gauge quickly, performing revision and upgrade studies at necessary points during modernization will increase line efficiency.

The machine is not in working order, can it still be modernized?

If the cause of the machine not working is a problem in the power and control equipment or controller, it is appropriate to modernize it. The correct operation of the key mechanical part is sufficient for modernization.

There is special equipment and apparatus on the machine. Can these equipment be controlled after it is modernized?

Yes, all apparatus and equipment can be included in the scope of modernization.

There are devices and devices on the machine that communicate with each other, can it still be modernized?

The systems we use support all communication and communication protocols. If there are communication protocol documents related to your hardware or if it is possible to get support from the manufacturer, the devices can also be adapted to the central system.

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Factory Digitalization

Technological advances brought about by the digital age are leading to revolutionary changes in the industrial sector. Traditional production models are now being replaced by more efficient, flexible and smart production systems. This is where factory digitalization comes into play to take the competition one step further. Digital transformation of factories plays a critical role in increasing competitiveness, reducing costs and increasing customer satisfaction by optimizing production processes. enables you to start digital transformation from the right point with the active management system developed especially for the extrusion manufacturing industry and film/sheet processing industry

Active management system is simply a real-time quality and productivity tracking system.

While ensuring quality production security, it also enables full performance measurement, including energy and production efficiency.

100% approved production concept

It brings a standard to the information flow and management model by combining machines with a closed control system that work independently of each other on a common platform within the framework of the new information system.

Real-time control

Unlike classical quality control performed on end-of-lot samples, it ensures that every quantity produced is within standards.

Synergy

The system establishes a continuous communication and recording bridge between the events tracked on the machine and the team.
  • Deviations out of tolerance that occur in the product and process are added to the production records.

  • Parameter changes made through the machine control system are added to the production records.

  • Time and material losses occurring in situations such as downtime / commissioning / production are added to the production records.

  • The monitoring scope can be expanded by adding additional measurement devices (e.g. energy measurement transformers, surface monitoring devices, etc.) to the system.

  • Real-time monitoring of anomalies and other events is provided from different platforms other than the machine control panel.

  • The production line forwards all preferred notifications to its own WhatsApp group. Departments such as quality, production, maintenance and planning are informed as soon as a problem/incident occurs. Team members take action within the framework of division of labor and give their feedback via WhatsApp group.

  • Operations such as commissioning, coil acceptance and coil rejection can only be carried out by authorized persons with personalized ID cards.

  • With the created reporting system, performance and quality data within the desired date range are reported on a work order and shift basis.

Productivity Increase

The new information system increases the efficiency of production processes with real-time data monitoring and analysis capabilities. It minimizes labor and energy losses by providing full-time control at every stage. In this way, operating costs decrease while productivity and profitability increase.

Production Optimization

The new information system integrates each step in the production line, offering an optimized production process. This allows the business to use resources more efficiently and reduces operational costs.

Quality assurance

The system monitors quality at every step in the production process, ensuring the production of accurate and consistent products. Thanks to real-time tracking and analysis, early detection of errors is possible, thus reducing the amount of defective products and increasing customer satisfaction.

Data analysis

The system creates detailed performance reports by analyzing the data obtained from production processes. These reports enable the business to evaluate production efficiency and support decision-making processes. Thanks to real-time data analysis, it is possible to optimize business management processes and gain competitive advantage.

Frequently Asked Questions

Are digitalization and creating an information system the same concepts?

Digitalization enables businesses to digitize physical processes and perform activities such as generating, storing and processing data with digital technologies. Receiving live data from machines is a method that businesses can use in this digital transformation process. An information system can be created to collect, store, analyze and report this data.

In summary, while digitalization transforms business processes, creating an information system is a tool used to manage and use the data obtained as a result of this process. Therefore, creating an information system by receiving live data from the machine can be seen as part of the digitalization process.

What are the minimum requirements to include a line or equipment in an information system?

At this point, solutions vary depending on the complexity of the line's functions. In systems with low-level data tracking, data is collected with externally added devices and sensors. In order to perform detailed analysis on complex lines, it is necessary to access all machine parameters. In this case, the relevant machine must have a structure that can perform at least one of the data sharing protocols. For lines with old technology and low control levels, it may be necessary to modernize the line before including it in the information system.

What is the difference of Erkinel information system from other service providers?

The system we produce is more focused on monitoring complex systems. It creates a production flow by tracking parameters on a work order and shift basis in continuously operating lines. The created flow not only provides lot-based tracking, but also enables complete work order-based analysis.

What is included in the scope of digitalization?

The project is created in line with your demands and the technical possibilities in your machinery park. Optionally, all auxiliary facilities, all production equipment (those that allow data sharing and/or lines that have a modernization project implemented before) and/or production area control points can be included in the system, or only extrusion lines can be monitored initially.

What are the technical support and service conditions after digitalization?

Technical support after project installation continues as lifelong support, including services such as database maintenance, new version updates, and system expansion in case your production/equipment park expands in the future. Support is free for the first 24 months after installation within the installation package, and continues for a fee in the following period throughout its life.

How is the project cost determined?

To determine the project cost, the project scope is first determined. When making choices here, appropriate hardware choices are made by taking into account the expansion potential. The main items that make up the cost are hardware, software, commissioning and technical support.

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For detailed information

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