EPIQ Machinery, a renowned provider of heavy-industrial material handling solutions, is revolutionising a sector traditionally reliant on manual labour and outdated systems.
The company is bringing the power of ‘Industry 4.0’ (a term for the modern era of automation and data exchange in manufacturing) to transform how materials are moved and managed.
“This isn’t just about replacing human workers; it’s about making factories safer, more efficient and more environmentally-friendly,” said an EPIQ spokesperson.
As a global company, EPIQ works closely with aluminium producers, a vital industry facing increasing pressure to reduce its environmental impact and boost productivity.
Its expertise lies in creating ‘integrated systems’ – essentially, connecting all the machines and processes in a factory into a single, smart network. Instead of isolated machines, it creates a system where every component communicates and shares data. For example, information from a robotic arm moving heavy aluminium components can be instantly sent to a central control system, allowing for real-time adjustments and optimisation.
A crucial part of aluminium production involves ‘anodes’ – large blocks of carbon used in the smelting process. The quality of these anodes directly affects energy consumption and pollution levels. So, EPIQ focuses on improving every step of the anode’s journey, from production to handling, cleaning, and inspection. The goal is to create smarter, more sustainable operations.
Many aluminium smelters lack a proper system for tracking each anode. This ‘anode tracking’ is like a detailed history of each anode, from its creation to its use in the smelting process. This lack of tracking makes it difficult to identify problems and improve quality.
EPIQ can implement systems that meticulously record the history and characteristics of each anode, providing valuable data for quality control and process optimisation.
One of the key innovations is ‘inline, real-time anode resistivity checking.’ This means users can instantly measure how well electricity flows through an anode as it’s being handled. Resistivity, in this case, is a measure of how much a material resists the flow of electricity and it is a key indicator of anode quality. This real-time data allows operators to immediately identify and address any issues, preventing costly downtime and ensuring consistent anode quality.
Automation is also transforming the way anodes are cleaned and inspected. Robots, equipped with advanced sensors and artificial intelligence, are now performing these tasks with greater precision and efficiency than humans. This reduces errors and ensures consistent quality. The company also uses ‘predictive maintenance’ which means using computer data to anticipate when machines will break, so they can be repaired or maintained before they cause problems, saving companies replacement costs and downtime.
EPIQ is also embracing the future with ‘Industrial Augmented Reality (IAR)’ and remote connectivity. IAR overlays digital information onto the real world, allowing workers to see data and instructions directly in their field of view. For example, a technician could see a diagram of a machine part overlaid on the actual machine, making repairs easier and faster.
Remote connectivity allows experts to provide support from anywhere in the world, eliminating the need for expensive and time-consuming site visits. This could involve an expert guiding a local technician through a complex repair via video link, with on-screen annotations and instructions.
“By integrating these cutting-edge technologies, EPIQ Machinery is not just keeping pace with the future; it is actively building it, driving a fundamental change in heavy industrial material handling,” concluded an EPIQ spokesperson.
All these technological advancements are designed to reduce environmental impact, increase efficiency and productivity, and improve worker safety in aluminium smelters.
For further information, visit www.epiqmachinery.com
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