Plastic foaming processes are extremely sensitive to temperature, pressure and flow. Even small fluctuations can cause inconsistent density and bubble size. Many plants rely on operator experience, making it hard to maintain stable quality over long runs.

In one foaming machine project, RB remote I/O was used for process data acquisition and control. The configuration 3×RB-1110, 10×16DI, 10×16DO and 4×AI works with temperature, pressure and flow sensors to regulate mixers, heaters and cooling circuits.

• Analog inputs continuously measure key temperature and pressure points;

• Digital outputs apply the PLC’s recipes and PID results to heaters, cooling valves and motor start/stop.

This allows the producer to digitize process recipes and implement them as “standard curves” in the PLC, while RB modules translate these strategies into actual field actions. Foam quality consistency and yield have improved noticeably, while energy consumption and manual inspection frequency have decreased.