Global Wind Blade Manufacturer
Rationalising composite manufacturing operations
Background
Our client’s global group is united in powering a cleaner world and unleashing limited energy. With 263,000 blades, manufactured in 9 countries, on four continents since 1978, almost every fifth turbine in the world is fitted with our clients Wind Power Blades.
They recognise that the manufacturing process comes with a footprint, and are determined to become leaner, greener and cleaner throughout their operations.
Challenge
Our client had already transitioned to infusion processes, using a variety of solutions and machines across their operations.
Committed to rationalising their setup and processes, they approached our expert team with the following questions:
- Can we improve our process control?
- Can we create one unified system that meets all of our requirements?
- Would that system be capable of manufacturing our large 78 meter blade?
- Can we automate our manifold flow?
- Can we automate and improve our data logging throughout the entire process?
Solution
Working closely with their team in India, our CI experts:
- Reviewed their production requirements and current setup.
- Scoped an optimised Infusion and RTM process to deliver to their requirements.
- Specified a CIJECT 5 machine
- Specified ancillary conditioning tanks.
- Specified a bespoke data system to monitor and optimise the end-to-end, automated process along with an ‘Integrated Control System’ (ICS) that can can control and monitor multiple machines and infusion manifolds.
- Installed the system and supported the factory and site adoption process.
- Provided ongoing operator training and preventative maintenance.
Results
Four CIJECT machines have been installed in their India factory, with a further four on order.
The operators are currently running a CIJECT blade production line, analysing the data and comparing its operational attributes with their other lines, using existing setups.
If the results are favourable, they will consider rolling out Composite Integration’s solution across their entire operations globally.
