United Process Controls, Waukee, Wis., reports that medical implants manufacturer Orchid Orthopedics, Memphis, Tenn., has modernized three Ipsen VFS vacuum furnaces with process control upgrades from United Process Controls (UPC).
Orchid was contending with underperforming controls that were compromising furnace efficacy, productivity, and uptime. Additionally, insufficient automation made it harder to push towards a paperless approach to reporting, traceability, and diagnostics. Looking to implement operational improvements that were in line with the company’s priorities, Orchid chose to retrofit two furnaces with replacement controls and retrofit a third furnace with a total control system replacement.
All systems feature Protherm 700 controllers, chart recording, and soft-start panels that were introduced to help lower energy costs during quenching. The upgraded systems include a recipe control system that incorporates specific programming for automatic leak test cycles and guaranteed soak for medical industry requirements – tasks that were previously monitored and recorded manually.
The improvements also make it easier for Orchid to streamline its maintenance process and manage maintenance tasks. This way, leak-up rates, events, and alarms are automatically and accurately reported. Moreover, upgrading with new controls and automation ensures that the company meets the more complex and stringent requirements of the U.S. Food and Drug Administration for medical implants.
“There was no need to start from scratch,” noted Rob Freeman, UPC services engineer heading the upgrade. “The furnaces are robust, but existing controls needed re-engineering to enhance the flexibility of operations and to meet specific needs in a cost-effective manner. By maintaining a focus on long-term operations, furnaces were upgraded to new business demands without incurring high upfront costs associated with new assets.”
Another key aspect of the upgrade was SCADA integration leading to unified operations. In the final stage of the project, the furnace controls were connected to the Protherm 9800 automation platform, which is configured to improve workflow efficiency, optimize furnace utilization, track work orders, and view real-time performance metrics.
