Is your tubular heating system ready for the next step in automation? For years, classic thermostats and simple temperature controllers have worked well in many installations, but growing market demands and the need for precise control are driving companies to implement modern solutions. Such a step was taken by our client - an experienced manufacturer and installer of heating systems for industrial installations, who wanted to increase efficiency, improve process supervision and prepare for the future challenges of Industry 4.0. In this case study, we'll show how switching to JUMO variTRON 500 touch PLCs allowed the customer to achieve greater flexibility, energy savings and full temperature control in tubular heating systems. If you're looking for ways to increase efficiency and better automate your system, keep reading to see how our solutions can help your business too!
In industry, precise temperature control is not only a matter of quality, but also of efficiency and economy. This is especially true for piping heating systems, where temperature stability is crucial for production processes in the food, chemical or energy industries. Many companies still rely on classic thermostats and simple controllers, which, although proven, have their limitations - lack of remote monitoring, data analysis capabilities or integration with other systems.
Meanwhile, growing market requirements and Industry 4.0 standards are forcing a change in the approach to process management. Companies that choose not to upgrade may face higher energy costs, greater risk of failure and limited flexibility of their systems. Modern PLCs open up entirely new possibilities - they provide advanced control algorithms, full data logging, remote monitoring and integration with SCADA systems. As a result, companies can not only better control temperature, but also reduce operating costs and prepare for future technology requirements.
The client for this project was an experienced manufacturer and installer of pipe heating systems that provides solutions to the food, chemical and energy industries. As a regional leader, it had always relied on proven technologies, but with the growing need for digitization and real-time process monitoring, the need to upgrade its temperature control system arose.
For decades, the company had been using our classic thermostats and temperature sensors, as well as simple temperature controllers to control the operation of heating cables. These were reliable and effectively kept heat in and prevented freezing in tubular heating systems, but they had their limitations - lack of remote monitoring, data analysis and flexible expansion. Every change required manual intervention, and faults were often discovered only after they had already caused disruption to the system.
To maintain its position in the market and adapt to new industry requirements, the client decided to implement a more advanced control system. Together we analyzed its needs and opportunities for modernization, concluding that a modern control system would not only increase the precision of temperature control, but also optimize costs and prepare the system for future automation challenges.
To meet the customer's new requirements, we proposed the JUMO variTRON 500 touch PLC, which offers a modular architecture and extensive integration capabilities. Compared to previous simple temperature controllers, the new solution provided greater control precision, configuration flexibility, and the ability to fully visualize the process on a touch panel.Thanks to continuous data recording and analysis, the customer gained better insight into the processes and was able to react faster to any deviations.
A key advantage was also the easy connection to SCADA and MES systems and support for multiple fieldbus systems, which made it possible to integrate the controller into the existing automation infrastructure. The built-in process visualization system allowed intuitive management of settings and real-time monitoring of system operation.
With remote monitoring and rapid fault diagnostics, operators were able to react faster to potential problems, minimizing the risk of downtime. As a result, the client received an advanced and scalable solution that not only increased the precision of temperature control, but also prepared its plant for further automation in line with Industry 4.0 requirements.
Implementation of the new control system provided the customer with greater process stability and trouble-free operation. Cost optimization through intelligent control allowed to reduce energy consumption, which translated into real savings. In addition, remote monitoring and diagnostics enabled rapid response to failures, minimizing losses.
The leader of the regional tubular heating market has proven that the digitalization of temperature control is not just a technology of the future, but a viable solution that brings tangible benefits today. The transition from classic controllers to PLCs has allowed for greater precision, savings and system reliability. This is a signal to the entire industry that control modernization is necessary if companies want to remain competitive. Digital control systems are becoming the standard, and this project is a perfect example that it's worth taking that step now.
Do you have a similar application? Contact us and learn more about our products and solutions for pipe heating!
My name is Ewelina Szmit and I have been working in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I unleash my creativity by creating newspaper collages. I like to spend my free time being active, walking my dog or running.
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