Category: Production control center


Quality and processes: dual mission for new control room

It is a long journey until blasted large-sized rock becomes usable cement. Crushing, grinding, drying and burning processes are necessary for this. In the new control center of Heidelberg Materials AG in the Ennigerloh cement plant, the quality of the product is now monitored in addition to these processes. Technical and ergonomic solutions from JST – Jungmann Systemtechnik® support smooth processes there.

A fully automated mechanism. In the raw mill, rock and lime are dried and finely processed like flour. Cement clinker is produced in burning processes, which is later ground into the final product cement. But in the event of a malfunction – for example if the temperature is exceeded – it is the control center drivers who have to decide what to do. 24 hours a day, seven days a week.

Interactive experience in the new control room: Zoom, rotate, nighttime view and change of perspective – here you can experience control room concepts in interactive 360 degree visualisations! How does the new control room look? How can the operator consoles be optimally positioned? How big should the monitor wall be? With professional 3D studies and virtual tours – here at Heidelberg Materials in Ennigerloh – these and many other questions can be answered at an early stage of the project. Light influences, colours, spatial conditions – there are almost no limits to the design possibilities. Go on a three-dimensional journey of discovery now!

"In the past, where all the cables ran together"

The task: product quality control and process monitoring – previously divided between two control room areas – are to be spatially bundled. “In the past, the control rooms were located where all the cables came together. For us, that was at the end of the kiln,” says Heinz Bröker, plant manager of the Ennigerloh cement plant. For us, that was at the end of the kiln,” says Heinz Bröker, plant manager of the Ennigerloh cement plant. “The control functions were very time-consuming for the staff,” explains the engineer.

JST reference HeidelbergCement control centre before conversion JST reference HeidelbergCement control centre after conversion

The rigid displays on a confusing number of individual monitors in the former control room of the Ennigerloh cement plant made the operators’ work unnecessarily complicated… …With the installation of the new control room and the associated technology concept, workplace monitors could be saved thanks to the flexible MultiConsoling® control system, thus realising an optimised overview.

Tasks are bundled with new technology

With the new solutions from Jungmann Systemtechnik, Heidelberg Materials is now setting the course for the future at the Ennigerloh location. Heinz Bröker: “Only the JST technology gave us the opportunity to bundle the tasks from all control technologies and thus enable the transition to a relaxed working environment.”

High demands on ergonomics in the control room

In addition to the control room specialists’ furniture solutions , which have been tried and tested hundreds of times, another convincing component is used to optimise sound levels and lighting: the OPAL X11® acoustic ceiling canopy with integrated HCL light source (Human Centric Lighting) for more concentration and performance. The sails are not only a visual highlight, they also create a perfect room atmosphere. Glare-free light and optimal acoustics,” says Heinz Bröker.

With myGUI ® "all systems effortlessly under control".

This positive summary is also due to the advantages of the new large display wall and the associated flexible control by JST MultiConsoling®. JST consultant Volker Weimer explains what makes the operation so unique: “Special JST CommandPads® are integrated directly into the operator consoles. With the myGUI® interactive user interface, they reflect a 3D layout of the entire control room infrastructure. This way, the control room operator has all systems under control effortlessly.”

Temperature and sound level effectively reduced

Another advantage: With the MultiConsoling® system, it is possible to outsource the entire technology from the control room. Heat and noise emissions are significantly minimised. A climate concept adapted to the possibilities of JST technology brings additional plus points for the working environment. Cool air is directed into the room under the large display wall and distributed diagonally upwards. Heinz Bröker comments: “The new climate concept is absolutely convincing”.

With all senses: "OPAL X11®" - THE upgrade for light and acoustics

JST Opal Acoustic Ceiling Sail Goals

Efficient reduction of the sound level in the room and glare-free, natural workplace lighting are just two of the convincing benefits of the new “Operator Acoustics Light – OPAL X11®. In cooperation with experts from the disciplines of room acoustics and lighting design, the JST experts closely oriented the development of the acoustic ceiling sail on the basis of occupational health specifications for shift operations to everyday control room conditions. The declared goal: a new level for the operator workplace. The result: an innovative and at the same time economical solution that serves to optimise concentration and performance with an integrated HCL light source (Human Centric Lighting). The choice of insulation materials used enables an 80 percent reduction in room sound. An integrated audio system also allows the user to receive visual as well as acoustic alarms.

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