Kingspan Ronneburg Production Line – Optimization and Development of Automation
Comprehensive engineering support in industrial automation, including PLC, HMI and SCADA programming, as well as diagnostics, for an operating Kingspan rock wool production line in Germany.
Client
Kingspan, Ronneburg (Germany)
Scope of cooperation
Industrial automation – PLC, HMI, SCADA, diagnostics, modifications, maintenance support
Implementation period
January 2025 – currently
Project languages
Polish, English
About the project
Project carried out for Kingspan, a global leader in the production of insulating materials, at their German rock wool factory in Ronneburg. Our aim was to raise the efficiency, reliability and comfort of operation of the existing production line through comprehensive modifications and programming Siemens S7-1500 PLC controllers. The initiative encompassed the development of new functionalities supporting production, precise calibration of systems, and the provision of ongoing diagnostic support.
Scope of work
Our involvement in the Kingspan Ronneburg project encompassed a wide range of engineering activities. We focused on modifying and optimizing the existing PLC, HMI, and SCADA software. A key element was also the implementation of new functions supporting production, which required an in-depth knowledge of the process and close cooperation with the client’s team. Additionally, we provided support in the area of programming KUKA robots, calibration and configuration of peripheral devices, and we also provided diagnostic services and technical support in emergency situations, minimizing line downtime.
Key elements of the scope
1) Development of functions supporting production
Implementation of new algorithms and operational sequences that streamline key stages of the rock wool manufacturing process.
2) Calibration and configuration of devices
Precise calibration of sensors (level, pressure) and configuration of Yaskawa inverters, ensuring optimal operation of machines.
3) Diagnostic support and troubleshooting
Provision of immediate support in the event of a failure, rapid fault diagnosis and minimization of production downtime.
4) Software modifications
Updating and expanding existing PLC programs (Siemens S7-1500), HMI visualization, and the SCADA system.
5) Optimization of existing solutions
Analysis and improvement of current automation processes to increase the efficiency and stability of the line.
Project challenges
Implementing the project on an operational production line was a key challenge, requiring our team to be flexible, precise, and capable of working under time pressure. The need to minimize production downtime, integrate with an extensive existing automation system, and dynamically resolve problems in a 24/7 environment required advanced technical skills and excellent coordination.
Main challenges
Technologies and solutions used in the project
| PLC controllers | Siemens S7-1500 |
| HMI operator panels | Siemens HMI |
| Visualization systems | Supervisory Control and Data Acquisition |
| Industrial robots | KUKA (2 units) |
| Inverters | Yaskawa |
| Sensors | VEGA (level, pressure) |
| Weighing systems | PEACOCK SYSTEMS |
| Programming environment | TIA Portal |
| Configuration tools | Yaskawa, VEGA |
Effects and benefits for the client
The most important results
• Improving the convenience of operating the production line.
• Shortening the diagnostic time for system faults (sensors, motors, robots).
• Facilitating operators in the daily operation of machines.
• Increasing the reliability and stability of the automation system.
• Streamlining the production process and increasing operational efficiency.
• Reduction of unplanned production line downtime.
Value added for the Kingspan factory
The implemented modifications and optimizations have significantly increased the operational efficiency of the Kingspan line, translating into higher production availability and lower maintenance costs. Shortened diagnostic time and increased system reliability have contributed to a long-term reduction in losses resulting from downtime. The project has also improved operators’ comfort at work, which has positively affected the ergonomics and safety of the workstations.
Why do clients choose us for projects?
Our experience in implementing projects on operating production lines, combined with deep expertise in PLC programming Siemens (S7-1500, TIA Portal) and KUKA robots were key to the success of this project. The ability to quickly and accurately diagnose issues, flexibility in adapting to the client’s specific requirements, and the emphasis on close cooperation with the local maintenance team and operators allowed us to deliver solutions that genuinely improved Kingspan’s production processes.
Summary
The project at the Kingspan Ronneburg factory is an example of effective optimization of an operating production line through advanced automation support. Thanks to precise software modifications, equipment calibration, and diagnostic support, we achieved a significant improvement in reliability, efficiency, and ease of operation, which directly translated into measurable business benefits for the client.
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