Plastics & Plastics Recycling
At DSI Innovations, we partner with companies to deliver comprehensive automation solutions for the Plastics and Plastics Recycling industries, helping to optimize their production processes and sustainability efforts. Our game changing expertise in extrusion and injection molding automation helps manufacturers increase efficiency and product quality, while our recycling line control systems and scrap reduction solutions enhance sustainability and minimize waste.
From quality inspection and sorting systems to robotic handling and packaging, we provide the tools you need to streamline operations and reduce environmental impact. So empower your company with the industry’s most outstanding strategists and project leaders who will help take you to the highest levels!
Our Plastics & Plastics Recycling Capabilities
Injection Molding & Extrusion
- Precision Temperature & Pressure Control: Using multi-zone temperature loops and closed-loop pressure regulation for consistent part quality.
- Screw Speed & Melt Flow Monitoring: Integrating sensors and inline rheometers to optimize throughput and material properties.
- Process Recipe Management: Standardizing parameters (temp profiles, cooling times, clamp force) to achieve repeatable results across shifts.
- Automated Material Feeding & Dosing: Implementing gravimetric or volumetric feeding for exact resin and additive measurements.
- Real-Time Data Collection & Analysis: Logging cycle times, shot counts, and part weights to identify trends and optimize runs.
- Advanced Servo or Hydraulic Controls: Balancing servo-driven movements or hydraulic pressure for faster cycle times and reduced scrap.
Blow Molding & Thermoforming
- Parison Programming & Control: Automating parison wall thickness profiles for uniform bottle or container geometry.
- Preform & Sheet Handling: Synchronizing conveyors, ovens, and forming stations to ensure precise heating and forming cycles.
- Multilayer Extrusion Monitoring: Ensuring each resin layer meets target thickness for barrier properties or branding requirements.
- Cavity & Mold Temperature Management: Using zone-based temperature control to ensure uniform forming and minimize warpage.
- Automated Trim & Deflash: Integrating robotics or servo cutters for clean edges and minimal waste.
- Inline Quality Inspection: Employing vision systems or sensors to detect wall thinning, voids, or other defects in formed parts.
Recycling & Reprocessing
- Shredding & Grinding Automation: Controlling shredder torque, feed rates, and safety interlocks for consistent material throughput.
- Washer & Separation Systems: Regulating water flow, temperature, and agitation levels to effectively clean plastic flakes or pellets.
- Pelletizing & Compounding Controls: Synchronizing extruders and pelletizers to maintain stable output and uniform pellet size.
- Contaminant Detection & Removal: Integrating metal detectors, color sorters, or X-ray scanners to isolate unwanted materials.
- Material Tracking & Batch Management: Logging recycled resin batches, including source material and contamination levels.
- Energy & Resource Optimization: Monitoring energy usage, water consumption, and overall process efficiency to reduce operational costs.
Quality & Process Control
- Inline Measurement & Inspection: Implementing sensors to track dimensional accuracy, color consistency, and resin flow properties.
- SPC & Statistical Analysis: Using software tools to detect trends or variation in critical process parameters.
- Batch Reporting & Documentation: Recording setup parameters and product specs for traceability, audits, or ISO compliance.
- Defect Detection & Classification: Employing machine vision to identify flash, sink marks, or surface blemishes.
- Traceability & Product Genealogy: Linking part serial numbers or batch codes to machine settings and raw material data.
- Alarms & Alerts: Configuring automated notifications when process variables deviate from established thresholds.
SCADA, MES & Data Integration
- Centralized Production Monitoring: Providing dashboards for real-time OEE, downtime events, and performance metrics across lines.
- Batch & Recipe Management: Standardizing process parameters for various resin grades or product types, ensuring consistency.
- ERP & Supply Chain Connectivity: Integrating real-time production data with material planning, order processing, and inventory management.
- Data Historian & Analytics: Storing high-frequency machine data for trend analysis, predictive maintenance, and cost optimization.
- Cloud-Based Reporting & Remote Access: Allowing authorized personnel to view plant KPIs or control systems from any location.
- Cybersecurity & Network Segmentation: Implementing firewalls, VLANs, and secure remote connections to protect critical equipment.
Safety & Regulatory Compliance
- Machine Guarding & Interlocks: Ensuring safe operation of high-speed cutters, extruders, or injection presses through integrated safety PLCs.
- OSHA & NFPA Compliance: Designing electrical panels and wiring practices that adhere to local and national safety standards.
- Lockout/Tagout Procedures: Implementing hardware and software solutions to safely isolate energy sources during maintenance.
- Environmental Regulations & Permits: Tracking emissions (VOCs) or effluent from washing systems to meet local environmental codes.
- Dust & Fume Extraction: Integrating extraction hoods and filters for airborne particulates, ensuring a safer work environment.
- Emergency Shutdown & Alarms: Configuring E-Stop circuits, audible alarms, and fallback controls for rapid response to critical events.
Upgrades, Retrofits & Migrations
- Legacy Migrations & Obsolescence: Removal of end-of-life hardware and unsupported systems to prevent downtime risks, ensure replacement parts availability, and secure long-term reliability through modern, vendor-supported solutions.
- Hardware & Software Upgrades: Incorporating new controllers, drives, sensors, or automation software to boost system reliability, integrate modern features, and future-proof operations.
- Retrofits & Expansions: Enhancing or reconfiguring existing equipment and systems to meet evolving production demands, address obsolescence, and capitalize on new market opportunities—all while managing costs and downtime through planned rollouts.
- Parallel Testing & Commissioning: Running new solutions in tandem with existing setups to minimize operational interruptions and verify functionality before full cutover.
- Hardware & Software Standardization: Unifying multiple control platforms, operating versions, and communication protocols to simplify maintenance, reduce training overhead, and streamline spare parts management.
- Phased Implementation Strategies: Scheduling major updates—mechanical, electrical, or software-related—over planned outages or staggered deployments, ensuring production continuity and optimized resource usage.
- Post-Upgrade Support & Optimization: Providing ongoing support after modernization, including system tuning, operator training, and performance reviews to ensure a smooth transition and long-term success.
Maintenance & Support Services
- Preventive Maintenance Programs
Regularly scheduled inspections and servicing to minimize downtime and extend equipment lifespan.
- 24/7 Technical Support & Emergency Response (with Support Contract)
Round-the-clock assistance to address urgent issues, available to clients who opt for a support contract.
- Post-Project Support
Included with every project to ensure a seamless handover and immediate troubleshooting once the system goes live.
- Field Services
Rapid dispatch of technicians to diagnose equipment issues, perform repairs, and restore functionality—minimizing disruption and downtime.
- Remote Monitoring & Troubleshooting
Real-time tracking of system performance to detect and resolve potential issues before they escalate.
- Staff Augmentation
Access to skilled professionals to fill short-term or specialized staffing needs for ongoing or complex projects.
- Software & System Upgrades
Regular updates to maintain optimal performance, ensure compatibility, and address emerging security concerns.
- Employee Training & Knowledge Transfer
Comprehensive support for in-house teams, covering best practices and hands-on training.
- Compliance & Safety Support
Guidance on meeting regulatory requirements and maintaining best practices for safe operation.
- Lifecycle & Asset Management
Proactive planning for equipment upgrades and replacements to optimize total cost of ownership.
Featured Projects
Case Study
REVOLUTIONIZING RECYCLING: Automation, Efficiency, & Reliability
Case Study
FROM OUTDATED TO OPTIMIZED: Seamless Migration of Legacy FactoryTalk Historian to Modern OS and Upgrade
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