Implementação de sensores de nível para controle do consumo de químicos em uma fábrica de latas

Abstract

The aluminum can package for beverage is a sector that has been growing a lot lately: according to Abralatas (Brasilian Association of Aluminum Can), in 2019, aluminum can was the package of 50% of beers produced in Brasil. The competitiveness on this market grows as new factories rise, therefore, to have a competitive advantage it is essential that guarantee that the processes happen in the most efficient and economic way. Having that in mind, solutions have been proposed focusing on solve one of the greatest problems in a can factory: metal exposure. Two main proposes was analyzed: the acquisition of a line to apply a second layer of varnish and the implementation of control process’ instruments to enhance trust of chemical products’ consumption quantities. To prioritize which action should be taken first, the quality assurance methods and monitoring and control processes were analyzed such as the economic benefit of them. The conclusion was that the acquisition of level sensor should be prioritized to enhance reliability of parameters recorded, because besides helping on metal exposure’s prevention due washing inefficiency, it also prevents it from occuring on varnishing stage, since varnish adherence depends on a proper surface’s cleansing and treatment. 8 level sensors (four for each washer machine) were purchased such as eight mobile support to optimize sensor’s fit when the vessels are replaced. With this initiative it is possible to have more precise data, automate level’s variance measurement and chemical products consumption tracking and mitigate inherent errors of manually executed work by people and non-eletronic equipments such as mitigation of safety risks. Data can be tracked and stored in real time, allowing the operational team to work in a preventive way rather than a reactive way. It was estimated a saving of R$348.000,00 and reduction of about 33% of metal exposure’s occurances. By the end of this paper, it’s clear that investing on processes’ automation and control instruments also means an investment on efficiency, safety and reliability.