Maguire + Syncro’s supervisory upgrade system, Syntrol Plus, brings together all elements of your line into one point of control.

• Connect all components & processes on your extrusion line
• Upgrade older, dated control systems
• User-friendly HMI – eliminate maintenance burden

Maguire + Syncro offers products to upgrade many aspects of an extrusion line, from materials blending and extrusion control, to Air Ring and APC upgrades, IBC width control, and full range of gauging solutions depending on the extrusion process.

Each modular component has its own independent PLC control, and several of these components can all be brought together in one supervisory control called Syntrol Plus, for an easy HMI experience for both new and seasoned operators, but making the line management simpler and easier than before.

Syntrol Plus is also available to upgrade the original OEM controls of a line, that 10 or 15 years later might be becoming harder to support in your location and or from the original supplier.

An upgrade to a line with Syntrol Plus essentially replaces all the original HMI and control processors, with the latest PLCs that are readily available from a spares and support point of view, and supported by Remote Assistance 24 hours a day. With the latest Syntrol Plus supervisory control, an old line can be integrated to the latest ERP systems, sync simply with cloud databases, provide 360 process reporting 24/7, and continue to evolve with the latest Industry 4.0 and IoT.

A line upgrade utilizes all the existing I/O on a line, such as heaters, drives, sensors, but simply replaces the older control hub with a new PLC platform, with an integrated, intuitive user friendly HMI.

Syntrol Plus upgrade for older line controls can renew the life of an older line and bring it to current day standards – improving control, operation, up time and productivity, and rapidly pays for itself.

Maguire + Syncro’s supervisory upgrade system, Syntrol Plus, brings together all elements of your line into one point of control.

Ancillary Components 

• Blender consumption and dosing units
• Air Ring control
• IBC control
• Line thickness & Gauging system

Line Components

• Extruder temperature & pressure
• Haul off control
• Web / cage control

Return on Investment

• Remote dial in assistance.
• Regular software upgrades.
• Easy to support with industrial components.
• Find spare parts.
• Exchange information.
• Improved control and increases production rates by 10% to 40% depending on line process and material, compared to a line without Syntrol Plus control.
• 5% to 15% gain versus simpler old control systems by better automation, regulation control, and data.
• Reduction of wastage in edge trims, reduction in handling and recycling costs.
• Reduction of labor interventions and management.
• Gains on start-up / reduction in materials scrap and wastage.
• Easier product changes and quicker setups and start-ups.
• Optimizes overall process with quick and effective control.
• Cost effective to deploy – typical return of investment within 12 months.

Simply send and receive data to a group of blenders.

• Know exact material usage / machine
• Create, update and send recipes remotely
• Full reporting by material, machine, recipe

G2 allows rapid two-way communication between a PC and the controllers of Maguire WSB Gravimetric Blenders.

Integration

• Gain full control of your Maguire WSB Blender range.
• Use G2 software as part of your materials management.

Control

• The blender measures and dispenses each material to ± 0.1% accuracy on a 1% setting.
• The blender eliminates over-coloring and increases control over product quality and consistency.
• G2 allows a blender user to fully document and visualize this for your process.

Materials savings

• Raw materials typically account for up to 70% of cost.
• WSB Blenders reduce costs by not over-coloring and maximizing on regrind usage.
• Blenders combined with G2 allow a processor to maximize on efficiency and minimize operating costs.

1. Build a Raw Materials List

• Simply build a complete list of all raw materials used in your process – either step-by-step or by import.

2. Create a Recipe Database

• Recipes can easily be built and updated from the raw materials list.
• Up to 35,000 recipes can be stored, saving production time, ensuring consistency and to act as a historical reference.

3. Send Recipes Directly to Blenders

• Simply send your recipe to the blender by clicking ‘Send to Blender’ from the Client screen.

4. See Live Production Status

• See live materials consumption by plant or by individual blender.
• View production information such as work orders, operators, and materials.

5. See Materials Usage Reporting

• Material usage reports can be run on a range of criteria that clearly show materials usage by process.
• Materials usage reports provides clear data for cost control and quality audits, such as ISO.
• Reports also help production plan more efficiently and technically troubleshoot any issues in regard to raw material usage.

With IoT and Industry 4.0, integrated manufacturing is ever the more important for effective and efficient control.

• Protocols available for majority of Maguire equipment
• Range of third-party integrations available
• Led by a broad range of customers & applications

Integration Benefits

• The value of integrated data for proper production planning and control contributes enormously to the planning and control of most plastics processors’ largest cost – raw materials.
• Many of Maguire products are available with communication protocol including products such as Maguire Gravimetric Blenders, Gravimetric Feeders, FlexBus Central Systems Control and ULTRA dryers.
• Benefits of active data provide far greater control and process understanding.
• For example, Maguire Maguire Blenders provides precise information on materials consumption allowing for better control of inventory, improved purchase planning, quality control, data for ISO and proper planning for job costing.

The Maguire G2 database can be located in a MySQL database server to allow customers to connect to third party interfaces, such as SAP, that connect to a MySQL database. MySQL is a stable, reliable and powerful solution with advanced features.

Ease of Use

• MySQL is easy to install and create recipes from. It can simply be added to many third-party tools that can be connected to the database.

Free Installation

• Should customers want to use MySQL with G2, installation is free and easily accessible.

Universal Platform

• The database is compatible with virtually every operating system to enable you to integrate with your current systems.

Extremely Powerful, Secure and Scalable

• MySQL is the de facto standard for high-traffic websites because of its high performance query engine, fast data insert capability and strong support for specialized web functions like fast full text searches.

Flexibility

• On-demand flexibility is a key feature of MySQL. This open source solution allows complete customization to those with unique database server requirements.

Anybus provides two-way communication between all Maguire Weigh Scale Blender’s MLAN protocol and 15 major networks.

Seamless Configuration

Anybus provide seamless conversion from MLAN Protocol to these 15 major fieldbus and industrial Ethernet networks:

• Fieldbus versions: Profibus, CANopen, CC-Link, ControlNet, DeviceNet, FIPIO, Interbus, Modbus Plus, Modbus RTU.
• Ethernet versions: EtherNet/IP, Modbus TCP, EtherCAT, Profinet, CC-Link IE Field, EtherNet/IP/MTCP 2-port.

Compatibility

• Compatible with all leading PLCs from manufacturers such as Siemens, Allen Bradley, Schneider etc.

Control

• Remote access to blender display and start / stop of dispensing.

Easy Setup

• Easily create set and get setpoints, types and parameters according to your requirements.

Maguire has developed profiles with Anybus. Anybus profiles are available to purchase from Maguire.

Machine Interactive Database

Digital supervision system for plant control and optimization.

ADVANTAGES

Maximize performance and minimize consumption

• Proactively optimize the performance of each machine and/or device.

• Measure efficiency and operational consumption.

• Simplify and speed up service interventions, even remotely.

• Possibility of integrating the collected data with company supervision systems.

FEATURES

Efficient and secure data acquisition and communication

• Remote control of machines with the possibility of changing working conditions.

• Data collection and information from machinery in a local database.

• Possibility of data access both locally and remotely.

• Readings and saving of real time and historical parameters, alarms and events.

• Possibility to connect with machinery and sensors not supplied by Frigel.

• Possibility to collect consumption data of monitored machines.