Category: Automation Solutions

Date: 2022-2024

Kayalar Copper Alloys Inc., established in 1958, has become one of the leading companies in Turkey in the production of sheets, strips, coins, and token blanks made from copper and copper alloys, with a commitment to technological advancement and quality understanding.

At Kayalar Copper, significant upgrades have been successfully completed as part of the Cold Rolling ABB 800xA Automation System revisions, including HMI upgrades, integration of the ABB thickness measurement system with the AGC (Automatic Gauge Control) system, and projects for data collection from production lines.

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Project Scope and Completed Projects

ABB 800xA HMI Revisions: The HMI system has been updated to provide a more intuitive and user-friendly interface for operators to monitor and control production processes. The new interface enhances operational visibility, allowing operators to respond more quickly to issues.

Integration of ABB Thickness Measurement System and AGC (Automatic Gauge Control): The ABB thickness measurement system has been integrated with the AGC system to ensure consistent thickness across all production lines. This integration allows for real-time monitoring and automatic adjustments during the rolling process, thereby improving product quality and minimizing material waste.

Production Data Collection Projects: Data collection systems have been implemented to gather real-time production data from various lines. These systems facilitate seamless communication with the automation infrastructure and provide valuable insights for process optimization, enabling better decision-making and proactive maintenance.

Category: Automation Solutions

Date: 2024

We have successfully completed the Engine and Transmission Line Project at Tofas, one of the leading companies in Türkiye’s automotive sector.

As part of the project, while our mechanical partner handled the installation of all conveyor lines, GNC Proses provided:

• Automation system development on Siemens PLC,
• Integration of drive and servo systems,
• Customization and installation of power and control panels,
• Installation and calibration of field sensors,
• Cabling and field installation services.

Through this project, we delivered turnkey automation solutions, providing Tofaş with advanced technologies to enhance production efficiency, reduce downtime, and optimize manufacturing processes. At GNC Proses, we take pride in leveraging our experience and innovative approach in the automotive sector to deliver a project fully aligned with Tofaş’s needs.

Category: Automation Solutions

Date: 2023

We have successfully completed the white goods production line modernization project at Beko Romania SA, which operates under the Arctic brand in Romania.

As part of the project scope, the following tasks were executed:

• Mechanical revision of the assembly and pre-heating conveyor lines to enhance operational efficiency.
• System automation through modifications to the existing Omron PLC to optimize control processes.
• Electrical panel upgrades and revisions to ensure system reliability and compliance with modern standards.
• Cabling and field installation to facilitate seamless connectivity across the production line.

This project was a comprehensive modernization effort aimed at improving production efficiency, reducing downtime, and increasing the reliability of the manufacturing process. GNC Proses’ experience in automation and system integration played a key role in delivering high-quality results, ensuring that the newly upgraded line meets current and future production demands.