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Transforming a high-speed paint line


An aluminium manufacturer needed to update the strip transport drive system on one of its high-speed paint lines. The existing DC drives were obsolete and due to the age of the relay control system, process improvements were difficult.

The project encompassed:

  • New line control system
  • Replacement 220Vac and 400Vac 3 phase distribution
  • Re-cabling of the line
  • New operator desks/stations
  • Removal of obsolete cables and equipment
  • Implementation with minimal disruption


Our Solution

Iconsys designed and built a 14-drive system utilising Siemens DCM, integrated via an S7-400 PLC based multiprocessor control system. Ancillary AC drives were selected from the Micromaster 440 range. Extensive use of remote I/O stations from the Siemens ET200S range minimised re-cabling work. The safe operation was implemented using ‘profisafe’ communication between an S7-400F safety processor and ET200M/S safe I/O. Other networks included Ethernet and Profibus.

New operator desks and control stations incorporated pcs running wincc Flexible HMI software. Operator visualisation was enhanced with new SCADA screens and all of the 3 phase 400Vac motor starters were replaced, including DOL, soft start and inverter technologies. Some of the plant and all building services were fed from a 3 phase 220Vac system. Where possible supplies were changed to 400Vac, with new ones provided elsewhere.



  • System back up and running with a minimum of downtime
  • Modern reliable, efficient and maintainable drive system
  • Reduced wiring


Client Feedback

The manufacturing plant manager is delighted with the process improvements provided by the Iconsys engineering team within a short and demanding project schedule. Improved line control has allowed the paint line to meet and exceed production expectations.

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Related Capabilities

iconsys enhance performance through integration of automation technologies.
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