EASY2 Change Q&A

Why was EASY2 Change developed?

Our analyses showed that the start-up and changeover processes are the main drivers of waste production. Following the launch of TURBOSTART in 2019 the development of another assistance system to support operators during these crucial production phases, was the next logical step for us.

Who is EASY2 Change for?

EASY2 Change supports operators through every step of a product change. Alongside other measures such as consulting and training, it is ideal for companies that perform a minimum of two product changes per day. It supports experienced operators and provides reassurance for less experienced operators to avoid costly mistakes.

What does it do?

EASY2 Change makes product changes reliable and repeatable. Ideal jobs are saved in the system and act as templates, we call these ideal jobs the “golden run". To get to this ideal point of production again the system guides the operator through the process, showing where action is needed to ensure nothing is forgotten. This ensures, that no settings and adjustments at the control panel are forgotten. Additional hardware features support operators in making safer and easier adjustments and provide information on the product´s status.

What are the main features of EASY2 Change?

First of all there is the EASY2 Change Dashboard in the control panel with a full overview and checklist. The system provides step by step guidance for all measures to be taken for the new (stored) recipe. Relevant settings cannot be forgotten.

Then there are two Cameras: One camera for Bubble Shape and the other for Frostline inspection both with target-actual comparison. The operator can see whether the product runs like the identical saved production or not. The system warns when tolerances are exceeded.

The Material Minimization Mode makes the change-over faster by reducing the material flow before the change-over.

Further features are:

• The fully automated Air Ring ARCTIS II, which makes manual intervention obsolete and recreates the predefined airflow settings in the air ring automatically.
• The EASY Change module, which automatically sets the predefined width and gauge settings of the product
• As well as the Profile Booster for faster good-production and the Purge Assist for faster purging of the machine

For which lines is it available?

EASY2 Change is available for new VAREX II and OPTIMEX II lines.

Is it retrofittable?

Yes, it is, to most lines installed after beginning of 2021. Our Salesteam or Retrofit Specialists can advise on the economic viability of an EASY2 Change retrofit.

When was it launched?

EASY2 Change was launched at K 2022.

What are the benefits for a company using EASY2 Change?

The benefits are overwhelming. The risk of incorrect settings in the control panel is reduced to zero. Compared to an experienced operator, 59% of time is saved (10 Minutes per job on average) and over 70% fewer clicks are required. All this thanks to the EASY2 Change dashboard in the control panel.

A saving of up to 90.000 kg material waste per year per machine is absolutely realistic (calculated based on 500kg/h output, 2 change-overs a day, 18 Minutes saved, 1.90€/kg resin costs).

Why would you recommend EASY2 Change?

There are plenty of benefits. Every product change is a potential risk. Especially if there are regular changes a forgotten setting or additive can have serious negative effects. These wrong settings are only human and can happen even to the most experienced operator. With the shortage of qualified employees, responsibility for several lines at a time, especially during night shifts, EASY2 Change serves as a safety net. Anyone can replicate the settings of successful jobs – regardless of the individual and their experience. The result is a stable and repeatable production.

In addition to human factors there are external factors such as quality of raw material or changing ambient temperatures, which have significant impact on the extrusion process. Here EASY2 Change detects deviations in the bubble shape or frostline height from the saved “golden run” which is the blueprint for all recurring jobs of the same product. If the bubble shows deviations, the operator can take corrective action.

And last but not least: sustainability, efficiency and economical aspects. EASY2 Change helps save time, save raw material, minimize reclamation and improves output quality and reliability for greater efficiency.