Projects
greenpet
Projects
Greenpet
The goal of the experiment
The goal of the GreenPet experiment, implemented in the frame of the AI Regio Project1 is to develop a software-hardware infrastructure for enabling a comprehensive monitoring, analysis and control of the eco-friendly quality of the PET bottle manufacturing process, through focusing on two main factors, which also define its environmental footprint: Energy and Emission. The system should be flexible and open for extensions, like introducing sensors for waste management (like camera-based visual quality inspection).
The duration of the experiment is eight months (02/2023-09/2023), with its main outcome of the GreenPET system, deployed and validated (using well defined KPIs) in the selected manufacturing SME (SME). It is important to emphasize that there is an ongoing cooperation between the technology provider SME (IT) and the selected pilot (USER). However, the ambition is to share this experience among many SMEs from this domain, using the network of DIHs, another asset which AI REGIO project is offering.
Main conceptual advantage of the experiment is the modelling of eco-friendly quality as a multidimensional concept, based on the information gathered from different data sources, i.e. considering all available parameters jointly, which requires multivariate analysis and more complex models. This is one of reasons why a data processing pipeline approach (like Data4AI) should be performed – a complex orchestration of different processing elements is required. Another advantage is real-time detection of anomalous situations in the multidimensional space, enabling a prompt reaction and waste reduction.
Two main technological advantages are
1) an efficient and non-invasive infrastructure for sensing relevant data, focusing on environmental aspects and welding process quality and
2) AI-based services for monitoring eco-friendly quality, process behaviour modeling and proactive detection of deviations.
Data pipeline (illustrated in Figure 1) will consist of the processing elements which
1) adapt different signals in a unified format (enabling their interoperability)
2) ensure the data quality by applying several methods for data cleaning (provided by Data4AI pipeline as described in Data4AI documentation)
3) enable reaction on real-time anomalies, which can be supported by AI REGIO technology asset from the Catalogue (D2 Anomaly Analyzer and Predictor) – e.g. notification in Grafana
4) learn models of process behaviour, which can be used for detecting process improvement potential 5) provide action handling based on the outcomes from the processing pipeline (based on gRPC)
Figure 1: GreenPET2 architecture based on AI REGIO technology assets
The solution introduces a new quality monitoring and control approach which a) can be easily created (affordable for SMEs) and b) accumulates experience and c) supports the detection of quality issues (before they escalate) and d) enables continuous process improvement.
Background
There is an ever increasing (market) pressure on manufacturing SMEs in EU to be in the same time very competitive and also eco-friendly. In the domain of manufacturing PET products this aspect is extremely important since manufacturing PET resin generates more toxic emissions (nickel, ethylbenzene, ethylene oxide, benzene) than manufacturing glass. Producing a 16 oz. PET bottle generates more than 100 times the toxic emissions to air and water than making the same size bottle out of glass. Even worse, most toxic releases went into the air, and the plastics industry contributed 14% of the national total (https://ecologycenter.org/plastics/ptf/report3/). The manufacturing process of plastic water bottles alone releases tons of carbon dioxide into the atmosphere each year. As a result, the surrounding oxygen becomes contaminated, making it harder to breathe and, in some regions, even making the residents sick.
However, SMEs producing PET bottles (incl. the selected pilot user for this proposal) are lacking the knowledge and experience in the context of organizing more environmentally friendly production.
background
There is an ever increasing (market) pressure on manufacturing SMEs in EU to be in the same time very competitive and also eco-friendly. In the domain of manufacturing PET products this aspect is extremely important since manufacturing PET resin generates more toxic emissions (nickel, ethylbenzene, ethylene oxide, benzene) than manufacturing glass. Producing a 16 oz. PET bottle generates more than 100 times the toxic emissions to air and water than making the same size bottle out of glass. Even worse, most toxic releases went into the air, and the plastics industry contributed 14% of the national total (https://ecologycenter.org/plastics/ptf/report3/). The manufacturing process of plastic water bottles alone releases tons of carbon dioxide into the atmosphere each year. As a result, the surrounding oxygen becomes contaminated, making it harder to breathe and, in some regions, even making the residents sick.
However, SMEs producing PET bottles (incl. the selected pilot user for this proposal) are lacking the knowledge and experience in the context of organizing more environmentally friendly production.
EXPERIMENT PARTICIPANTS
INNOMINE (partner DIH) – Hungary
innomine is a leading innovation management expert in Central and Eastern Europe who brings knowledge, research and consultancy services to clients by helping connect startups and small/medium sized enterprises with financial funding support for innovation programs. It is specialised in digital innovation, Industry40 and acceleration programmes/projects and has a cross-disciplinary team of professionally qualified consultants, with research and consultancy expertise in management, technology, European funding and business development. As a Digital Innovation Hub, innomine actively collaborates with multiple key European initiatives along with 2000+ small and medium sized enterprises.
innomine is currently member of 5+ major European digital innovation and ecosystem development related programs: 1. Cloudifacturing, which aims to boost the adoption of cloud solutions by manufacturing SMEs; in the project innomine acts a CEE Digital Innovation Hub. 2 DIH4CPS – innomine’s role is to lead experiment implementation (as DIH), lead communication and dissemination activities, contribute to set up a European DIH network and service portfolio.
Dr. Gábor Vicze,CEO of innomine is an entrepreneur with 15+ years of experience in digital industries gained from startups, scaleups and also multinationals. He has a strong innovation, public funding and policy background (including European policies, H2020 and structural funds). He possesses a solid research background and strong international network. As a senior innovation strategy expert, Gábor Vicze often acts as mentor, coach, public speaker. Gabor Vicze is/was member of boards for multiple industrial associations and organizations (e.g. DIGITALEUROPE, ICT Association of Hungary).
Centroplast D.O.O (partner manufacturing SME) – Serbia
Role: Manufacturing SME, Pilot Definition DIH, dissemination, DIH networking, also supporting the definition of business services systems development, IoT integration, maintenance, running and validating the pilot.
Company for the production of plastic packaging, trade and services, Centroplast D.O.O. was founded in 2005 by B.Sc. Dragan Pantić, who started producing plastic packaging in 1995 (centroplastnis.com). The primary activity of Centroplast is the production of PET (poly-ethylene-terephthalate) packaging, while the secondary activities are related to the production of PE and PP packaging. The business is based on the use of high quality non-recycled materials, modern product design, professional technical knowledge and customer care with a tradition of more than twenty years: 100,000,000+ bottles shipped so far and the maximum monthly production capacity is 800,000 bottles.
From idea to realization in 20 working days:
– Centroplast approaches 3D modeling and submits the model (s) to you for verification – Technical preparation and production of matrix – mold for blowing packaging
– Production and submission of test samples for verification
– Verification by the client
– Contracting and delivery of desired quantities of packaging
ADA SYSTEM DOO NOVI SAD (partner IT) – Serbia
Founded in 1992, ADA represents a modern IT organization which uses high-tech technologies for resolving complex industrial problems. Well-recognized technology provider for advanced data processing, complex event processing (CEP) and real-time big data analytics. Current innovation focus is on dynamic event processing networks that support early detection of complex situations in a global context, which can be used for developing proactive big data architecture. There are many successfully developed domain-oriented solutions: ADALed for the intelligent control of street lights, ADAGPS for the intelligent navigation, ADAPDA for the mobile control of remote resources in manufacturing environment. There are more than 50 customers who are using the solution for many years, including big manufacturing companies, transportation organizations and retailers. The application domains range from wearables-based eHealth (remote patient monitoring), through IoT- driven intelligent transportation till Cyber-Physical Production systems (flexible manufacturing), with the main focus on creating dynamically responsive systems that can sense and respond timely (or even ahead of time). Offering end-to-end software services for real-time monitoring, local processing (Edge) and efficient data transfer to the server (Cloud) and complex big data processing/analytics in order to get useful recommendations for managing monitored entities (closed control loop).
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