Client Challenge
A major recycling plant in Las Vegas, NV, needed a state-of-the-art plastics sorting line to improve sorting efficiency, reduce manual intervention, and handle increasing throughput demands. The project required the integration of equipment from 5-10 different Original Equipment Manufacturers (OEMs) while managing the operation of 200-250 motor loads.
Additionally, the system needed to meet Nevada’s permitting and compliance standards, all while adhering to a tight timeline. The complexity of integrating diverse systems from multiple suppliers posed a significant challenge, along with the need for precise control and seamless communication between components.
Our Solution
To meet the client’s needs, DSI delivered a turnkey solution, leveraging its expertise in industrial automation. Key aspects of the solution included:
- Electrical Design and Compliance: DSI created custom designs for PLC, I/O, and VFD control panels, ensuring all electrical panels were UL-compliant. State-stamped single-line power drawings were developed to meet Nevada permitting requirements.
- Subcontractor Management: DSI supervised the entire electrical installation process, managing subcontractors to ensure high-quality work while maintaining the project schedule.
- Programming and Integration: Using Siemens PLC and HMI systems, DSI programmed the control systems to meet the end-user’s specific operational requirements. The solution ensured seamless integration of the equipment supplied by 5-10 different OEMs.
- Commissioning Support: DSI collaborated closely with a German OEM and other sub-suppliers to commission all equipment, achieving flawless system startup and functionality.
Through its methodical approach and attention to detail, DSI delivered an automated sorting line that was ready for full operation on time and within budget.
The Results
DSI’s solution transformed the recycling plant’s plastics sorting operations, enabling:
- Improved Efficiency and Accuracy: The automated system allowed for higher throughput and more accurate sorting, significantly reducing manual intervention.
- Regulatory Compliance and Safety: Nevada-stamped drawings and UL-compliant panels ensured adherence to all regulatory requirements.
- Operational Reliability: The coordinated control of 200-250 motor loads across equipment from multiple OEMs resulted in a robust, integrated system that exceeded the client’s expectations.
The project’s success resulted in three additional purchase orders for sorting plants in the Midwest, Southwest, and Mid-Atlantic regions. Each project will replicate the Las Vegas plant’s scope and complexity, with DSI continuing to provide permitting, panel fabrication, and commissioning expertise.
By meeting the client’s needs with precision and reliability, DSI not only delivered a cutting-edge solution but also solidified its role as a trusted partner for automation in the recycling industry.
