Challenge

A prominent manufacturer of irrigation products aimed to improve the efficiency and reliability of its production line for the irrigation sprinkler heads. The existing system presented significant challenges, such as frequent troubleshooting and extended downtime due to complex wiring methods. Traditional wiring required discrete wires between the control cabinet and machinery, leading to cumbersome installations, increased labor costs, and production delays. Moreover, the customer experienced limitations in their network setup, specifically running out of IP addresses for devices on the factory floor.

Solution

Valin’s involvement in this project began through Valin’s Sun Automation team collaborating with the integrator. The team proposed a retrofit of the production line using IO-Link modules, which offered a streamlined and efficient solution for transmitting digital and analog signals. By leveraging Balluff IO-Link modules, the customer addressed their IP address limitation issue and improved operational efficiency.

The IO-Link solution was implemented across key sections of the assembly line. These modules enabled quicker installation through connectorized sensors and allowed for shorter wire runs, significantly reducing labor and installation time. The new system acted as an electrical barrier between devices and controllers, protecting the PLC’s I/O board from potential damage due to electrical shorts.

The ease of use and flexibility of the IO-Link system convinced the integrator and the irrigation manufacturer to proceed with the solution. The sales cycle was relatively short, as the benefits of IO-Link—such as reduced installation time and enhanced diagnostics—were clear to all stakeholders, and transition with their existing controls platform was seamless.

Customer Benefits

Reduced Downtime: With IO-Link, troubleshooting became faster and less disruptive to the production process. Fewer issues arose during operations, minimizing downtime and keeping the production line running efficiently.

Enhanced Protection: The system’s electrical barriers protected control components, safeguarding the PLC’s I/O board and reducing the risk of costly repairs.

Streamlined Installation: Modular, connectorized sensors made the installation process smoother and faster. By reducing wire counts and utilizing shorter wire runs, the system's integrator was able to cut installation time from two weeks to just four days, resulting in significant labor savings.

Improved Flexibility: The IO-Link system provided more flexibility for future expansions. With the ability to easily integrate additional devices without the need for complex wiring or consuming extra IP addresses, the customer could scale their system as needed.

Long-Term Outlook

Encouraged by the success of the initial IO-Link deployment, the customer plans to expand the use of IO-Link throughout the rest of the production line. The ultimate goal is to outfit every station with network hubs, further reducing downtime caused by sensor or valve failures, enhancing system diagnostics, and achieving even greater operational efficiency.

Although the customer did not perform an official ROI calculation, the long-term benefits of enhanced productivity, reduced labor costs, and minimized equipment damage were clear and substantial. These advantages demonstrate the significant impact of adopting modern automation technologies like IO-Link in improving manufacturing operations.

Conclusion

By implementing IO-Link technology, the manufacturer took significant steps toward improving production efficiency, reducing maintenance costs, and enhancing overall operational reliability. This case study illustrates how modern automation solutions like IO-Link can deliver powerful results, streamlining installation, safeguarding equipment, and supporting the scaling needs of advanced production environments.

Be sure to read our blog: Unlocking Production Efficiency with IO-Link Technology: A Solution for Manufacturers

Challenge

A high-volume manufacturer of custom electrical cabinets for the car wash and solar power industries needed a more efficient production process. Previously using Phoenix Contact products, the company faced inefficiencies, particularly in assembly and labeling, leading to increased labor costs and delayed project timelines.

Solution

Valin, in partnership with WAGO, introduced WAGO products in late 2023. The customer established a "WAGO Station" with WAGO components and a free printer promotion, enabling them to streamline pre-assembly and labeling. WAGO’s Smart Designer software simplified panel designs, and TOPJOB® S terminal blocks enhanced workflow efficiency. SmartScript software further optimized labeling accuracy and speed.

Customer Benefits

Enhanced Efficiency: The WAGO Station allowed the customer to pre-assemble and label components ahead of time, significantly reducing assembly times and increasing productivity.

Simplified Panel Design: WAGO’s Smart Designer tools sped up integration of components into panel designs, reducing time spent on drafting.

User-Friendly Tools: The flexibility of TOPJOB® S terminal blocks, with toolless features, minimized errors and further reduced assembly times.

Improved Labeling Process: The SmartScript software simplified and accelerated the label creation process, enhancing overall production efficiency.

Customer ROI and Savings

With the special pricing agreements (SPA) that Valin secured, the switch to WAGO became more cost-effective than Phoenix Contact, resulting in improved ROI. The total value of the orders placed in 2023 approached a million dollars.

Future Outlook

WAGO products are now standard for the customer’s projects, including their fan air systems, car wash lines, and larger projects. WAGO’s role in the customer’s operations continues to grow, solidifying the customer’s commitment to using WAGO solutions moving forward.

Conclusion

The partnership between Valin and WAGO has enabled the customer to streamline their production process, reduce assembly times, and increase operational efficiency. The switch to WAGO products has positioned the customer for continued growth and success in the competitive custom electrical cabinet manufacturing industry.
 

Challenge

A leading custom control panel provider for the carwash industry faced significant challenges in maintaining operational efficiency for their customer’s carwash systems. These systems required precise control over conveyors, dryers, and spinning mops. Initially using ABB and Siemens drives, they struggled with long lead times and rising costs. Furthermore, they needed more durable, reliable, and energy-efficient Variable Frequency Drives (VFDs) to reduce downtime. Their customer, a large carwash chain with operations across the U.S. and Canada, needed efficient controls for various pieces of equipment.

Solution

Valin introduced Mitsubishi’s D700 Series VFDs to the customer in 2018.  After reviewing the new VFDs, the customer recognized that Mitsubishi’s D700 Series would address the current issues they were facing. Initial testing on smaller projects led to a major shift in the company’s control systems. The customer initially placed orders for 15 VFDs (ranging from 2, 3, and 5 HP). The D700 Series offered a new architecture that allowed for smaller horsepower motors while maintaining consistent output, solving the customer’s immediate need for reliable performance and quicker availability compared to ABB and Siemens drives.

As the orders grew from dozens to hundreds, the customer began integrating Mitsubishi VFDs across various aspects of their production line, controlling critical equipment like conveyors, dryers, and spinning mops. Mitsubishi's VFDs were strategically positioned in their systems to manage the precise speed and direction of conveyor belts and auxiliary equipment.

The key to success was Mitsubishi’s ability to deliver durability and energy efficiency, even in demanding environments like carwashes. Their customer was impressed by the adaptability of the VFDs and the seamless installation process, making it an ideal solution for improving operational efficiency.

Benefits to the Customer

Reliability and Durability: Mitsubishi's D700 Series VFDs have proven highly reliable, with no warranty claims or component failures over the past several years. The robust design of the VFDs has made them well-suited for the rigorous demands of carwash environments, handling vibrations, temperature changes, and heavy-duty operations.

Energy Efficiency: Mitsubishi’s VFDs are designed for maximum energy efficiency, dynamically adjusting power consumption based on the load. This adaptability has led to significant energy savings for the carwash chain, contributing to their overall goal of sustainability and regulatory compliance. This energy-conscious design also reduces operational costs by optimizing power usage across the facility.

Lower Total Cost of Ownership (TCO): Mitsubishi’s VFDs come with a 5-year warranty and a 10-year maintenance-free design, significantly reducing the total cost of ownership. The combination of cost savings and reduced downtime has provided a substantial return on investment for the customer.

Seamless Scalability: As the carwash chain expanded, the customer continued to standardize Mitsubishi VFDs in their facilities. Mitsubishi’s flexibility allowed them to integrate the D700 Series across various systems, ensuring consistent control and performance as their operations scaled.

Sales Cycle

The sales cycle for this transformation began in late 2018 when the customer placed their first order for Mitsubishi D700 VFDs because that is what was available. Valin’s Sun Automation worked closely with the customer to demonstrate the value of Mitsubishi's solutions. Impressed with Mitsubishi’s reliability and cost-effectiveness, the President made the decision to integrate Mitsubishi VFDs across all projects, standardizing the product line moving forward.

Even during the COVID-19 pandemic, Mitsubishi VFDs proved critical to the carwash chain’s operations. Though supply chain issues briefly caused the customer to source cheaper drives from China, they returned to Mitsubishi in 2023 once supply stabilized, citing the unmatched reliability of the D700 Series. The customer continues to use Mitsubishi VFDs to this day.

Customer ROI and Savings

The customer experienced significant cost savings with Mitsubishi’s VFDs. Mitsubishi drives were more affordable than their previous ABB systems. The customer has placed nearly $200,000 worth of orders for Mitsubishi products in 2023 alone. Additionally, Mitsubishi’s lower long-term maintenance requirements and energy-efficient design resulted in reduced operational costs, further improving their return on investment.

Conclusion

The transition to Mitsubishi’s D700 Series VFDs has enabled the customer to overcome supply chain challenges, reduce downtime, and improve energy efficiency. The reliable performance and scalability of Mitsubishi VFDs have made them the preferred solution for their operations. With Valin’s support, the customer continues to grow and expand, placing Mitsubishi VFDs at the core of their carwash operations across the U.S. and Canada. Mitsubishi’s drives have proven critical to maintaining the efficiency, reliability, and profitability of the customer’s systems, securing their competitive position in the industry.