Modernization of Morein Plastics' compounding systems by BSG

Automation Technology How Retrofit Ensures 24/7 Production

2025-12-17 Source: Bruckmann Control Technology | Translated by AI 2 min Reading Time

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After around 15 years of continuous operation, the company Morein Plastics is modernizing its compounding systems with the support of BSG. By specifically replacing the automation technology, production was made future-proof, and reliability was significantly increased.

The PLC and HMI program was completely redeveloped and designed for a uniform, intuitive user interface.(Image: Bruckmann Control Technology GmbH) — The PLC and HMI program was completely redeveloped and designed for a uniform, intuitive user interface.
(Image: Bruckmann Control Technology GmbH)

Two compounding lines from the company Morein Plastics, in 24/7 operation for around 15 years, had reached their technical limit. Recurring electronic issues in the old PLC recently led to several production downtimes—a risk the company was no longer willing to take. The mechanical basis of the systems was largely preserved and renewed where it was technically or due to wear and tear deemed sensible. For automation, the decision was made to undergo targeted automation modernization by BSG.

Following intensive consultation with BSG, a concept was developed that optimally utilizes the existing setup while bringing the control technology completely up to date. BSG has already successfully completed the modernization of one of the two lines: in addition to the new PLC and HMI hardware, conveyor technology, silos, and dosing scales were fully integrated. The PLC and HMI program was entirely newly developed and designed with a uniform, intuitive user interface.

Gallery

This is how the control cabinets looked before modernization.(Image: Bruckmann Control Technology GmbH)

This is how clear and structured the control cabinets look after modernization.(Image: Bruckmann Control Technology GmbH)

With the modernization by BSG, we have taken an important step towards future-proofing. Our system now operates stably, efficiently, and is up-to-date with the latest automation technology. We were particularly impressed by the practical advice and the smooth implementation.

Willem Reinink, Managing Director of Morein Plastics GmbH

Production Environment at the Cutting Edge of Technology

The conversion of the second line is imminent. Following the successful modernization of the first system, it is already evident how reliable and user-friendly the new automation is. All functions of the integrated components can now be centrally controlled via the new HMI. With the upcoming modernization of the second compounding line, the production environment will be uniformly structured and technologically brought up to date—an important step toward efficiency, reliability, and future-proofing for 24/7 operation.

With over 30 years of experience in the automation and digitization of plastic production systems, BSG is one of the leading specialists in the industry. The project at Morein impressively demonstrates how proven plant technology can be economically and future-orientedly utilized through targeted modernization.

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