pioneer process Control
Intelligent process control for maximum efficiency in extrusion
KraussMaffei Extrusions new machine control concept, pioneer processControl (ppC), is now being rolled out across all our systems. With a modern, user-friendly design, ppC makes daily operations intuitive, efficient, and safe. A consistent layout with always-visible headers and footers provides clear structure and fast access to key functions. The Siemens-based PLC ensures high performance and flexibility, while the unified HMI guarantees a familiar experience across all applications.
Design Awards
Customer Benefits
- Clear error messages with comment features
- Individual and clear trend display with comment feature
- Easily readable key production values
- Workflows for starting and stopping production
- Automatic screensaver highlights imported values and messages
- A consistent layout with always visible headers and footers
- Process monitoring from multiple devices with comment feature
- ppC – Connectivity:
- Connection of the ppC control system to customer systems (e.g., MES or DCS) via OPC UA as standard
- Standard read access to actual and target machine values
- Flexible connection via additional protocols such as Modbus TCP or Profinet, depending on project requirements
- Adjustable integration depth according to project needs
- Remote control of the plant via a DCS possible
- Easy integration of the ppC user interface into third-party systems or control rooms through web server options
- PWO – Production without operator:
- Integration of features to actively assist operators
- Ready for the era of the 'dark factory'
Why choose pioneer processControl from KraussMaffei?
Our new machine control system is characterized by a modern, user-friendly design.
The clear and structured layout enables intuitive navigation and supports operators in their daily tasks. The consistent design approach of the ppC layout, with containers and a permanently visible header and footer, ensures reliable and process-safe operation. The header provides essential information such as production status, the loaded recipe, and active messages.
The footer mirrors the machine layout and offers quick access to key functions of individual units, allowing operators to interact with the system efficiently.
The PLC is Siemens-based and offers a high degree of flexibility for high-performance applications.
Applications
Pipe and Profile
The system guides the user step by step through the process - like taking them by hand. This structured approach helps prevent mistakes and reduces the risk of errors during critical situations such as machine startup.
Compounding
Compounding includes all essential machine components - from raw material feeding and accurate dosing through the extruder, to downstream equipment such as strand pelletizing, UWG, and finished material handling. Measuring systems for quality monitoring are also part of the setup.
Foam
Foam includes all essential machine components — from raw material feeding and precise dosing, through the extruders, to downstream equipment such as the sheet calibrator and systems for order picking (sawing, packaging units), all the way to finished material handling. Integrated measuring systems for quality monitoring are also part of the solution.
Sheet
Sheet includes all essential machine components — from raw material feeding and precise dosing, through the extruders, calenders or smoothing units, and cooling systems, to downstream equipment with several types of winders. Integrated measuring systems for process control and quality monitoring are also part of the setup.
Technology Center
We invite you to discover our newly developed ppC control system, designed to set new standards in process transparency, connectivity, and operational efficiency. At our Technology Center in Laatzen, the system can be experienced live in operation on three extrusion lines: foam extrusion, film extrusion, and compounding.
The ppC system features a clear and user-friendly interface, with intuitive error messages and trend displays - both enhanced by a practical comment function. Key production values are presented in a clearly structured format, supported by workflows that simplify start-up and shutdown procedures. A consistent layout with permanently visible headers and footers ensures a seamless user experience.
Highlights include multi-device process monitoring, automatic screensaver displays of key data, and a high degree of system integration flexibility. Through OPC UA, the ppC control system connects easily to customer MES or DCS environments. Depending on project needs, other protocols such as Modbus TCP or Profinet can also be supported.
Remote access, integration into external control rooms, and even remote system operation may be possible.
With integrated functions that support operators and enable stable production with minimal manual intervention (PWO – Production Without Operator), the ppC system brings future-ready automation into today's extrusion processes.
Visit us and experience the new ppC control system in real production conditions – we look forward to welcoming you at our Technology Center.
Turnkey Solutions
In addition to our advanced control technologies, we offer complete, turnkey extrusion systems tailored to your specific production needs. Our ppC-System provides a fully integrated, ready-to-operate solution, already available for a wide range of applications. Our current portfolio of turnkey systems with our ppC-System integrated include pipe-lines, compounding lines, foam lines, recycling lines and PVC pelletizing lines. Within the coming months, there will also be a specific solution for sheet lines.
All systems are engineered for optimal interaction between hardware and software, ensuring smooth operation from day one. From material handling to process control and downstream integration – we deliver complete solutions, tested and ready for commissioning.