PVC Compounding Reimagined

From raw material to the finished mix. Automated, transparent, and digitally connected.

A modern PVC compounding plant is much more than silos, scales, and mixers. It is the heart of your production.

With OPDENHOFF, we connect raw material handling, dosing, weighing, mixing processes, material transport, and production data into a continuous digital material flow.

For more transparency. More process security. Less complexity.

Your PVC compounding as a continuous process

From the arrival of the raw material to its delivery to the extruder, every step must securely interlock.

Therefore, we consider not just individual machines or controls, but the entire value stream:

Raw material delivery → Silos → Big bags → Bagged goods → Dosing → Weighing → Hot mixer → Cooling mixer → Material transport → Day bins → Extruder

All relevant data will be connected along this process.

This creates a continuous view of:

Raw materials, formulations, orders, batches, scales, mixers, silos, plant statuses, quality, and traceability.

Fully automatic instead of unnecessary complexity

Our philosophy is clear:

The process is the focus. Not the software.

Operators should be able to focus on their production, not on complex control systems.

That's why we're reducing on-site service to the essentials:

Clear plant images. Simple panels. Automatic processes. Unambiguous messages. Secure user guidance.

OPDPRO.CARE takes over the overarching orchestration.

This way, the system landscape can become significantly simpler and at the same time create more transparency.

The digital material flow of your PVC production

With OPDPRO.CARE, a digital twin of your entire material flow is created.

Each batch can be digitally tracked:

What raw material was used?

Which silo did the material come from?

What amounts were dosed?

Which formulation was produced?

Which mixer was the batch run on?

What process values were available?

Which extruder was the material transferred to?

This creates end-to-end traceability from raw material to finished product.

The plant connects production, quality, and maintenance

A modern PVC compounding plant generates valuable data. It is crucial not to isolate this data in individual systems.

OPDPRO.CARE connects:

Production
Orders, recipes, batches, quantities, and plant status.

Quality
Setpoints, tolerances, process values, and deviations.

Maintenance
Assets, Electrical Cabinet Assignment, PLC, SCADA, EPLAN, Documentation, and Maintenance.

Management
Productivity, consumption, downtimes, throughput, and process indicators.

This way, all participants work with the same data, but with their own view of the process.

From the individual asset to the control cabinet

Every motor, every valve, every scale, and every mixer can be represented as a digital asset.

The asset contains, for example:

Manufacturer, Type, Serial Number, Technical Data, Maintenance Information, Documents, Spare Parts, SPS assignment, SCADA visualization and EPLAN reference.

Through the assignment to the control cabinet, a direct connection is created between mechanical processes, electrical engineering, automation, and IT.

One asset. A unique identity. All relevant information in one place.

Retrofit or new PVC compounding

Whether it's an existing mixing facility or a greenfield project, we start with the real process.

For existing systems, we check:

Which components can be further utilized?

Which controls need to be modernized?

What data is already available?

Where do unnecessary manual work steps arise?

How can the existing plant be digitized step by step?

Our goal is not to replace everything.

Our goal is to meaningfully connect the existing with the new.

Open. Flexible. Freely selectable.

We rely on open interfaces and avoid unnecessary vendor lock-in.

Depending on the project, we connect, among other things:

Siemens PLCs, existing control systems, SCADA systems, ERP systems, OPC UA, MQTT, REST APIs, SQL databases, scales, mixers, dosing systems, and other production equipment.

This way, your PVC blending will remain expandable in the future.

Fewer systems. More transparency.

Consistent simplification of the system landscape can significantly reduce hardware, licensing, IT, and OT expenses.

Simultaneously, the following arise:

More process security.

More traceability.

More transparency.

Less manual intervention.

Less dependence on individual manufacturers.

A common database for the entire production.

Over 55 years of experience in automation and process industry

From analog controls, SIMATIC S5 and S7 up to modern digital twins, edge systems, and AI:

OPDENHOFF combines decades of experience in plant and control engineering with modern digitalization.

We don't just know software.

We are familiar with control cabinets, PLCs, scales, mixers, raw materials, plants, and the realities of production.

This is precisely why we always consider your PVC compounding as a whole.