The value of partnerships

The company’s authority in thermal technologies has facilitated partnerships with other leading players in the sector. In this context, it is particularly interesting to explore the impact of these collaborations in a crucial area for the global market: the production of semiconductor devices. 
Since the birth of the first diode, temperature has played a crucial role in semiconductor manufacturing processes. The solutions developed by CD Automation for its partners are based on a deep understanding of the technological processes that form semiconductors. In particular, as the dimensions of these devices have shrunk, temperature has become an increasingly critical variable in the production process.

What is a semiconductor?

The fundamental characteristic of semiconductors is reflected in their name: they are materials whose electrical conductivity lies between that of metallic conductors and insulators. They represent a rather broad and heterogeneous category of substances, highly sensitive to light and characterized by a negative temperature coefficient of electrical resistivity. This means that their conductivity increases as temperature rises, unlike metallic conductors.
The main reason why semiconductors are so useful is that their conductivity can be modified through the addition of impurities (doping), the application of an electric field, or exposure to light. 

The semiconductor device crisis

In recent years, the semiconductor sector has experienced a period of strong instability, initially linked to supply chain difficulties that emerged in the post-pandemic period and that particularly affected consumer electronics and the automotive industry. Although the most critical phase of the “chip shortage” has gradually eased, the market continues to be characterized by complex dynamics and highly uneven demand across different application sectors.
From these considerations, it becomes clear that the most accurate term is not simply “chips,” but “dispositivi a semiconduttore”, a term that identifies the entire family of fundamental components of modern electronics (transistors, diodes, and power devices) and which represents the foundation on which industrial electronics has developed and continues to evolve.

How are semiconductor devices manufactured?

The manufacturing of semiconductor devices refers to the process used to produce the chips and integrated circuits found in most modern electronic devices. This industrial process is carried out through multiple stages involving photolithographic and physicochemical technologies, during which circuits are gradually built on a substrate called a wafer, made from a single crystal of ultra-high-purity semiconductor material.
To create an integrated circuit, an extremely homogeneous wafer is required, free from discontinuities that would compromise component quality. The most widely used semiconductor in the industry is monocrystalline silicon (meaning it has a uniform crystal structure throughout the material), grown using the Czochralski technique.

The Czochralski process

This process consists of the vertical lifting and simultaneous counterclockwise rotation of a properly oriented silicon monocrystalline seed, introduced into molten silicon at 1425°C by means of a metal rod, while the crucible rotates in the opposite direction.
In this way, a small amount of molten material in contact with the seed cools and solidifies according to a crystal structure identical to that of the seed. As the seed is pulled upward, more material solidifies in the same way, producing a single-crystal ingot.
The silicon temperature in the crucible is kept only a few degrees above its melting point, and by adhering to the seed crystal it solidifies very quickly, preserving the seed’s structure. Strict control of the molten material temperature, the chamber atmosphere, the extraction speed, and the complete absence of vibrations allows the production of perfectly cylindrical and highly pure ingots

The float zone method

However, the previously described method has a limitation: silicon tends to react chemically with crucible materials. For this reason, it is preferable to obtain silicon single crystals using the floating-zone technique.
In this case, the ingot is fixed at the upper end to the upper chuck, while its lower part is brought into direct contact with a monocrystalline seed held by the lower chuck. The process begins by creating a molten zone in the part of the ingot in contact with the seed, which is then slowly moved upward. The silicon that solidifies in contact with the seed faithfully replicates its crystal structure. 

Defect removal

The next step consists of cutting the ingot using diamond wires to obtain discs a few tenths of a millimeter thick: wafers. The resulting slices have surface imperfections that are removed through a series of processes (grinding and lapping).
The final processing step is chemical etching, which removes the last surface defects, producing monocrystalline wafers ready for component fabrication.

Photolithography

At this stage of semiconductor device manufacturing, complex patterns must be miniaturized and printed onto the wafer through a process known as photolithography.
Initially, the wafer is coated with photosensitive chemicals (photoresist), which harden when exposed to light. A light beam is then projected through a photomask, creating a light image of the circuit. This image is passed through a series of lenses that reduce it to the correct scale and project it onto the wafer.
The light reacts with the photoresist, which is then washed away, revealing an underlying oxide layer. This oxide layer is further etched using acid, exposing the silicon beneath. The exposed silicon is then subjected to a process called doping, which alters its electrical properties.
This process is repeated multiple times, with different combinations of chemicals and masks, until the semiconductor devices are built layer by layer.

Property enhancement

Some layers are baked, others are blasted with ionized plasma, and others are immersed in metals. Each treatment modifies the properties of that layer and gradually forms part of the puzzle that makes up the chip design. Finished silicon wafers contain billions of circuit elements and thousands of individual microchips.

Semiconductor device manufacturing: a continuously evolving sector

A full understanding of these semiconductor manufacturing processes is essential to face the many challenges of a rapidly growing sector that is deeply involved in the evolution of thermal technologies. It is precisely with this goal in mind that CD Automation provides its know-how and offers a family of universal power controllers for semiconductor device production.

The characteristics of REVO C

REVO C, in the 30 to 2100 A range, is a high-performance power controller for power regulation, adaptable to all SCR applications and equipped with an advanced microprocessor that makes it universal and fully software-configurable.
It is also one of the most complete units in the range thanks to:

• three-phase synchronization, phase rotation diagnostics, phase-angle firing, current limiting, and high measurement accuracy;
• integrated Profinet communication and reduced integration times thanks to TIA Portal libraries; Ethernet/IP communication with dedicated libraries to simplify integration;
• SCCR 100 kA – 600 V (Short Circuit Current Rating) certification, in compliance with UL508 standard.

The main advantage of the REVO C power controller – which makes it particularly suitable for semiconductor device production – is its ability to connect easily with the external world via Bluetooth and the most widely used industrial Fieldbus protocols. Its versatility allows configuration of inputs, firing modes, and control logic directly from a smartphone or personal computer.
Designed and built as a single compact unit, REVO C not only reduces the overall footprint and the time required for assembly and wiring of separate fuses, but also ensures proper execution of testing phases and easy access to printed circuit boards, fuses, and thyristors.

Do you need suggestions to make your thermal control processes in semiconductor manufacturing more efficient and competitive? Contact us and book a free consultation session with one of our experts. You will receive strategic proposals to enhance and extend the lifetime of your heating systems while minimizing downtime.

Extrusion: what is it?

The plastic extrusion process takes its name from the equipment used: the extruder, according to the operations and elements we will describe: from the feed hopper, the polymer enters a cylinder; here it is melted, homogenized, and pushed forward by a screw until it reaches the extruder head, which shapes it as desired. The product, exiting the machine, is cooled using water or air. Subsequently, the plastic is rolled or cut to the desired dimension.

Extrusion: a thermal procedure

The material used in the extrusion process is thermoplastic. It becomes soft when heated and hardens during cooling.
But how is the heat necessary for extrusion obtained? The heat is generated mainly by the friction produced by the screw, driven by a motor, as it rotates in the plastic mass, and only partially by the heaters present in the cylinder.

Focus on the extruder cylinder

The cylinder used in extrusion is divided into several zones, each equipped with heating and cooling control systems, which ensure the temperature required for the process. These temperatures are not the same as the plastic inside the cylinder, although similar measurements are recorded along the head and die. Each zone is characterized by a specific thermal requirement. Special attention is required for the rear zone of the cylinder, near the hopper feed: it affects the feed rate and production speed.

Extruders: single screw or twin screw?

Most extruders are single screw. The extension of this system is expressed by the length/diameter ratio, where production levels are directly proportional to the screw length.

The screw can be divided into three zones:

• feed zone: the depth is constant and sufficient to transport the plastic granules.
• compression zone: the depth decreases as the screw diameter approaches the walls, increasing the pressure on the plastic and preventing air formation between the granules inside the cylinder.
• metering zone: the plastic is almost completely melted and ready for final mixing and extrusion through the die. This zone has a constant depth, smaller than that of the feed zone.

Single-screw extruders are complemented by twin-screw extruders, consisting of two intermeshing screws inside the cylinder. This type is further divided into two subcategories depending on the rotation direction of the screws: co-rotating for co-rotating twin-screw extruders and counter-rotating for counter-rotating twin-screw extruders.

How to operate extruders?

Extrusion machines are usually driven by AC drives, known as inverters. Interventions on frequency allow adjusting the motor speed, which is higher than that required to move the screw. Therefore, it is essential to reduce the speed transmitted by the motor, acting on the combination and size of pulleys and gears. This intervention allows operation at a speed, and consequently a power, close to the maximum value.

Thermal regulation of the cylinder

As mentioned earlier, the cylinder temperature is controlled along its entire length by different single- and dual-action control loops; the first manage only electrical heating, the latter also cooling.
A control loop consists of the following elements:

• a temperature sensor (a J or K thermocouple).
• a controller with sensor input and several outputs to control the actuator.
  Multiple control loops can be integrated within a multi-zone controller or as a library inside a PLC. The controller can also manage the cooling part by connecting one of its outputs to a fan. Cooling can also be achieved using an external chiller and a heat exchanger, via water or oil.
• an actuator (usually a solid-state relay).
• one of the following heating elements: band heaters with ceramic or mica insulation, armored tubular heaters in aluminum casting, cartridge heaters connected in series, quartz infrared lamps, and die-cast electric heaters.

Functions of heaters

Heaters perform five key functions for the extrusion process:

1. allow a safe start, avoiding potentially harmful “cold starts” for the equipment.
2. compensate for radiation loss during operation.
3. control, maintain, and vary mold temperature.
4. reduce resistance, lowering viscosity on internal metal surfaces.
5. heat the emerging surface for higher gloss.

The value of temperature control systems

From these preliminary considerations, the strategic importance of an efficient, continuous, real-time temperature control and management system is evident. A system that must be initially designed based on the type of process, the chosen material, and the scrap rate, and secondarily calibrated according to the specific needs of different zones.

A family dedicated to extrusion

The REVO family from CD Automation offers a complete solution for controlling plastic extrusion processes. Thanks to its modularity and versatility, REVO adapts to both compact lines and complex industrial plants, ensuring precision, reliability, and ease of integration with existing automation systems.
Within the family, the REVO C series stands out for its flexibility and compactness, ideal for optimizing space in electrical panels without sacrificing power or performance. REVO C is designed for multi-zone temperature control, essential for keeping the molten mass stable and ensuring the quality of the final product in extrusion, co-extrusion, or compounding.
REVO C units integrate advanced functions such as load diagnostics, resistance monitoring, and fault protection, reducing machine downtime and improving production continuity. Full compatibility with major fieldbuses and automation systems allows high-performance, tailor-made solutions, providing concrete support to manufacturers and system integrators.

Optimizing Power Quality

CD Automation supports its partners with customized Power Quality projects to reduce disturbances on the power line, cable heating, and energy losses. For extrusion process efficiency and sustainability, the company has developed the multichannel REVO PN power unit, capable of managing applications with multiple power zones. Thanks to the power distribution algorithm, REVO PN can balance and limit the requested current peak, maintaining high absorbed current quality while reducing losses and consumption.

The role of REVO PN

Using REVO PN in extrusion processes significantly reduces power peaks, keeping them below contractually agreed levels and avoiding penalties or unforeseen expenses.
The unit manages up to 24 heating elements. By synchronizing the switching of all channels, voltage peaks can be avoided, keeping the power factor close to 1.
Additionally, each module can autonomously communicate with the most common fieldbuses and promptly detect heater failures and thyristor short circuits.

CD Automation offer for extrusion

CD Automation guarantees a complete offer for managing thermal regulation and power in plastic extrusion operations, through the development of automation packages that provide integrators with a solid base to customize. Packages include: supervisor, software, PLC, Melt temperature and pressure control, Melt and temperature sensors.
CD Automation also provides packages for managing laboratory extruders or small extruders with 4 to 16 control zones, ensuring complete solutions for operator panels, rear or panel-mounted temperature controllers, counters, timers, or sequencers.

Do you want to discover how to make your extrusion processes more efficient and competitive? Contact us and book a free consultation session with one of our experts. You will receive strategic and personalized proposals according to your needs.

Drying: a thermal process

Basically, heat is required to apply various coatings such as paint and colour. The function of infrared lamps is in fact to ensure the drying of wet water-based coatings and to accelerate the melting process of powder coatings. To optimise the result, it is essential to adapt the infrared emitter to the characteristics of the product to be heated, in terms of wavelength, shape and power. Correct adjustment of the radiation enables rapid absorption of the paint, avoiding overheating and ensuring protection of the material and the environment.

The steps in paint drying

Paint drying is a process normally consisting of two phases: a first, purely physical phase during which the evaporation of solvents (water, hydrocarbons, alcohols, ketones) occurs, and a second, chemical phase in which the polymerisation of the resins (binders) contained in the paint is achieved.
Not all paint products require the chemical phase: thermoplastic (or non-crosslinkable) products finish drying with the evaporation of solvents. In contrast, thermosetting (or cross-linkable) products also have a polymerisation phase.

The steps in paint drying

The drying of paint products generally takes place in an oven, in which the temperature depends both on the type of product, the material of the painted surface and the type of technology adopted.
Drying can be carried out using different equipment:

• gas-fired bare-flame heating panels;
• gas heating panels by catalytic combustion without flame;
• electrically heated tubes, lamps and radiant plates;
• microwave irradiation.

The many advantages of infrared drying

Infrared lamps are able to produce targeted, direct heat on surfaces, ensuring even and rapid drying, for an impeccable result in terms of both aesthetics and protection. In addition, the advanced operation of these heating systems means that moisture is eliminated and operation is based on electricity, which does not require the use of chemicals or fuels, which are harmful to health and costly to the pockets of contractors. This advantage means that infrared lamps can also be used in the presence of flammable substances, such as paint, ensuring the safety of workers.

A radiation in resonance with the material

For the benefits listed above to occur, however, it is necessary that the electromagnetic radiation emitted by infrared lamps is absorbed by the molecules of the paint product. In other words, it is necessary that the energy carried by the radiation is able to induce a vibration in the molecules, known as molecular agitation, with a consequent rise in the temperature of the material.

Since the proper vibrational frequency of a molecule depends on its structure, for IR rays to be easily absorbed, the wavelength of the radiation must be synchronised, i.e. resonate, with that of the material of which the paint product is composed.

Automotive requirements

Industrial painting is a process that is widely used, particularly in the automotive sector, an area that is constantly striving for speed and increased production. The targets set by the sector require a drastic reduction in paint drying times. And it is precisely in the enterprising search for a solution for the automotive industry that the prestigious know-how of CD Automation comes into play.

A tunnel for drying railway carriages

The company, based in Legnano, took part in the design of a tunnel for drying and annealing paints, using infrared lamps, on railway carriages. This paint drying technique was for the first time successfully applied to such large areas, accommodating the customer’s request to increase productivity by converting the existing oven and thus avoiding the construction of a new plant.

Paint drying with infrared lamps: plant design

To reduce paint drying times and increase productivity, two parallel walls consisting of 59 zones each were installed, with two short-wave infrared lamps per zone, for a total of 236 lamps of 3750W and a total system power of 0.9 MW.
The conversion of the hot-air oven to one with IR technology has produced an amazing result: a production time reduced by 12.5 times compared to the performance of the previous convection oven. The total time spent in the oven by the carriage undergoing the industrial painting treatment has in fact dropped from 100 to 8 hours, corresponding to just one working day.

CD Automation’s contribution to paint drying

CD Automation’s team of experts has structured a precise infrared lamp management and control system for the correct management of the power used in paint drying.
The system set up by CD Automation consisted of three REVO PN 24 multi-channel power units and as many REVO PN 12 multi-channel power units and made it possible to:

• optimising consumption;
• monitoring electrical variables;
• early diagnosis of heating element breaks and short circuits on thyristors;
• fieldbus communication.

REVO PN’s valuable contribution to paint drying

CD Automation’s REVO PN unit makes it possible to significantly reduce power peaks, keeping them below contractually agreed levels and avoiding penalties and unexpected expenses.
REVO PN is a modular product, capable of handling up to 24 heating elements. By synchronising the switching on of all channels, problematic voltage peaks are avoided and the power factor is kept close to 1.
Last but not least, REVO PN’s “Dynamic burst firing” mode reduces flickering in short-wave infrared lamp applications.

Want to find out how to make your paint drying processes more efficient and competitive? Contact us and book a free consulting session with one of our experts. You will receive strategic proposals tailored to your needs.

The electrification of processes

Let us now try to clarify the reasons for the last statement, pointing out, first of all, the benefits of electrical processes.
The technologies involved in electrothermal systems allow for an integral utilisation of heat, without losses, i.e. without the transition from a higher to a lower temperature source, according to the laws of classical thermodynamics.
Moreover, electrothermal processes do not generate harmful emissions of nitrogen oxides, carbon dioxide or sulphur.

The main advantages of industrial electric boilers

• Emission-free operation: Steam production is entirely powered by electricity, eliminating combustion and related emissions.
• High operating efficiency thanks to precise modulation with thyristor technology.
• Cost reduction and simplification: The absence of fuels, flue gases and chimneys significantly reduces installation costs, space requirements and maintenance interventions.
• Customised reliability: Engineered solutions tailored to the specific operational needs of each company.
• Smart integration: I sistemi di controllo avanzati si integrano facilmente con le infrastrutture esistenti, consentendo una gestione ottimizzata dell’energia disponibile.

Getting to the heart of the matter, industrial electric boilers convert electricity into heat or steam. All incoming electrical energy is converted into thermal energy, with an efficiency close to 100 per cent, if minimal radiation losses are excluded.
Compared to processes mediated by fossil fuels, electrically driven processes ensure rapid start-up and uniform boiler heating, but also accurate control of temperature and steam pressure.
In particular, precise pressure control with multiple power stages allows the boiler to react quickly to load variations, ensuring fast start-ups to absorb available grid power when needed.

Environmental respect and comfort

As they do not consume fossil fuels, industrial electric boilers do not release gaseous effluents into the atmosphere, making them safer. This advantage facilitates their installation: they do not require chimneys, fuel supply networks or storage tanks.
In addition, they do not require periodic monitoring of atmospheric emissions and operate quietly, another detail not to be overlooked for a sustainable environment, where the degree of noise pollution must also be taken into account.

Efficient simplicity

Industrial electric boilers offer numerous advantages both in terms of performance and construction, and for periodic maintenance. As anticipated, they are designed to allow rapid start-up and steam production, protecting the heating elements from sudden stresses.
In addition, industrial electric boilers have a robust construction and a wide range of adjustments, ensuring safe and long-lasting operation. This feature, coupled with the ease of cleaning compared to gas boilers, means that maintenance and operating costs are significantly reduced.

The push for renewables

In conclusion, with the development and deployment of grid-integrated renewable energy sources such as wind and solar power, unplanned production peaks should be mitigated; given also new trends and some new regulations in several European countries that promote self-consumption rather than feeding electricity back into the grid.
With the use of electric boilers, excess electricity can be used intelligently to generate heat and steam in industrial processes, according to an energy storage process that is becoming increasingly important for the energy transition.

Investing in competence to increase business competitiveness

This multiplicity of benefits is driving companies to supplement and replace traditional boilers with electric boilers. A competitive and sustainable solution that, in such a complex period, limits the vulnerability of industries to energy price fluctuations.
However, it must be considered that electrothermal energy is a complex sector, requiring advanced knowledge spread over several disciplines: electrical engineering, thermal engineering and materials science. It is therefore necessary to rely on competent partners for the electrification of systems and operations.

Why focus on CD Automation?

Choosing CD Automation gives you access to a team of experts who have been working for over thirty years to reduce consumption and complexity and improve the power quality of their customers’ industrial processes. The company manufactures thyristor power units and soft starters of the highest quality, with the support of a system of subsidiaries and partners that are leaders in the industrial thermoregulation sector worldwide.
Through these products, CD Automation ensures the reduction of power line disturbances, heating of electrical cables and energy losses. Three strategic benefits in the area of monitoring the operation of industrial electric boilers. In particular, the control system designed by CD Automation makes it possible to maintain power factor values close to 1, avoiding energy cost penalties.

The proposal

Let us now go into the details of CD Automation’s offer for manufacturers of electric boilers for industrial use. The Legnano-based company offers the series REVO C and REVO S three-phase, with currents from 60 to 800A. But it also offers the use of a synchronisation system that combines the REVO PC unit with the REVO S series.

The REVO C series consists of high-performance power control units, adaptable to all SCR applications, equipped with an advanced microprocessor that makes it universal and fully configurable via software.
REVO C is the most complete unit thanks to:

• three-phase synchronisation, phase rotation diagnostics, phase angle switching, current limit, measurement accuracy;
• integrated Profinet communication and reduced integration time using ready-to-use TIA PORTAL libraries. IP Ethernet communication with libraries to reduce integration time;
• SCCR approved 100kA – 600V (Short Circuit Current Rating), according to UL508.

The REVO S family consists of high-performance, reliable, flexible and compact SSRs with the following properties:

• nominal voltage 480-600-690V;
• SSR or analogue input already configured;
• Burst Firing (Fast Zero Crossing);
• Heater Break alarm to diagnose partial or total load break or thyristor short circuit;
• internal fuses that reduce wiring time and panel size.

For the intelligent management of electrical loads, REVO PC, the multi-channel power controller is used to optimise consumption and power factor.
This intelligent device can manage up to 24 single-phase zones or 8 three-phase zones.

With the REVO PC unit you can:

• eliminate instantaneous power peaks,
• keeping instantaneous power below the companies’ contractual limits,
• setting less onerous contracts and avoiding penalties for exceeding these limits,
• manage REVO S units with a simple SSR input.

Conclusions

Industrial electric boilers, integrated with innovative CD Automation technologies, represent a strategic solution combining environmental sustainability, operational efficiency and tangible economic benefits for companies committed to sustainable growth and operational excellence.

Would you like to receive more detailed information about the proposals developed by CD Automation for industrial electric boilers? Contact us and book a free consultation session with one of our experts. You will receive strategic indications to optimise the energy efficiency of your products and services.

The partnership with CO.RAM

CD Automation presents a video on its channel produced in collaboration with CO.RAM, a company that has been manufacturing furnaces, melting and holding furnaces, and metallurgical treatment plants for over thirty years. CO.RAM, a strategic partner of CD Automation for several years, has extensive expertise in addressing challenges related to light alloy metallurgy, a relatively new field that undergoes continuous and exciting innovations.

A delicate transition

The biggest change in furnaces for the metallurgical treatment of light alloys is the transition from gas heating systems to electric systems. This is a change that is as necessary as it is challenging, requiring not only new skills but also timely and continuous support between companies. Hence the need to forge strategic partnerships, in a two-way exchange of know-how that enhances the authority of the entire sector.

Resistive elements and silicon carbide: limitations and solutions

Delving into the specific application, CO.RAM turned to CD Automation for the correct management of the resistive elements used in electric heating systems. The main objective of the partnership was linked to the need to deliver the maximum possible power to the system without compromising the operation and integrity of these resistors.

To date, silicon carbide is the most efficient resistive element. It has the highest specific power rating on the market; however, its crystalline structure imposes significant limitations in terms of fragility and power degradation.

To compensate for this fragility, CO.RAM has adopted the latest generation of CD Automation power units, which include a soft-start function. This function allows the output power to be limited over a certain period of time or to ramp up to the set point when the control is activated, in order to avoid thermal shock to the heating elements.

The problem of power decay for resistors in electric heating furnaces has been solved by using a leading product from CD Automation: REVO C. This unit can be connected to configuration software capable of analysing all the electrical data of the process and configuring the parameters necessary for the optimal use of silicon carbide heating elements, compensating for voltage in a linear manner in order to maintain power at a near-constant level.
The advantage offered by the REVO C unit is therefore crucial, as it extends the lifespan of the silicon carbide elements.

Consumption monitoring

The REVO C power regulator meets another primary need for companies operating in the metallurgical treatment and smelting furnace sector: energy calculation. Through configuration software, data loggers and the most widely used field buses, the unit allows strategic data to be acquired on process variables such as voltage, resistance, current, power and absorption, in order to verify the efficiency and correct functioning of electric heating processes.

Control at your fingertips with your smartphone

The service offered by CD Automation also meets some of the objectives of Industry 4.0, a paradigm that encourages the use of remote assistance to reduce production costs, minimise maintenance downtime, optimise on-site solutions and streamline processes.

In line with this objective, CD Automation has developed a new app, available for iOS and Android, which facilitates the connection of REVO C units with smartphones. The app can detect the various units within Bluetooth communication range, reporting operating and electrical parameters, as well as an analysis of energy consumption during the process. It also allows users to enable, disable, and configure features, as well as control the operation of the various units.

Thanks to this app, the CD Automation team can provide top-level support to operators who interface with power units, displaying parameters in real time and suggesting the most appropriate solutions.

To learn more about these topics and the comparison between CD Automation and Co.RAM on electric heating, watch the full interview video with english subtitles.

Would you like to learn more about how REVO C can make the thermoregulation processes of your electrically heated melting furnaces more efficient and sustainabl? Contatact us and book a free consultation session with one of our experts.

What does revamping mean and why is it important?

Revamping is the renewal of the electrical and electronic components of industrial machinery. This upgrade does not affect the mechanical parts of the machinery or production plants, since it makes little sense to intervene on components that are still functional and crucial for product quality.
It is also important to note that upgrading control and automation systems is much more cost-effective, as these tend to become obsolete before mechanical components. This electronic renewal can also be applied when acquiring used machinery to be installed on a production line or resold, bringing its performance close to that of new equipment.

Better results, but with the same machinery

Through targeted replacement and refurbishment of electrical panels, PLCs, and obsolete drives, revamping can streamline the production of an industrial plant. By keeping the original machinery, companies can take advantage of the latest generation of industrial automation solutions without needing to retrain personnel.
Revamping applies not only to individual machines but also to entire industrial plants that need to be upgraded or restored to working order.

What are the advantages?

Revamping can deliver all the benefits of new machinery while reducing costs by up to 50% and minimizing machine downtime.
Key advantages include:

• extended service life of machinery;
• increased productivity and plant performance;
• lower energy consumption and improvement in energy efficiency;
• enhanced personnel safety;
• improved product quality and production flexibility;
• reduced production and maintenance costs.

The energy sector

The industrial sector is increasingly interested in and willing to invest in revamping industrial energy plants to modernize and regenerate production facilities. This type of revamping is seen as a strategic opportunity to boost competitiveness on a global scale. Efficiency gains have multiple benefits, including increased competitiveness, reduced environmental impact, and improved brand reputation.

The industrial rise of electricity

A major driver of this trend is the transition from gas heating systems to electric heating systems. Electric systems convert electrical energy into heat for industrial processes, using principles such as electric arcs, resistance heating, dielectric losses, microwaves, infrared radiation, plasma, and lasers.
Electrothermal equipment offers excellent opportunities to increase productivity, energy efficiency, and competitiveness. In many electrothermal processes, heat can be fully exploited without losses, avoiding the classical thermodynamic issue of transferring heat from a higher to a lower temperature source.

What are the benefits of electrical processes?

In addition to energy efficiency, electrical processes provide significant environmental advantages. Electrothermal systems do not produce harmful emissions such as nitrogen oxides, sulfur, or carbon dioxide.
Compared with conventional fossil-fuel heating, electrical processes also offer:

• rapid and uniform heating, precise temperature control, and almost instantaneous start-up and shutdown;
• high-quality end products;
• the ability to create new products, particularly in the chemical and electronics sectors, which are difficult to achieve with conventional heating;
• increased productivity and reduced production costs;
• reliable production processes with simplified control and monitoring;
• automation opportunities for production lines and small-scale industrialized processes;
• safe working conditions for employees.

Why partner with CD Automation?

The electrothermal sector is vast and complex, requiring advanced knowledge of electrical and thermal engineering, as well as materials science. For this reason, when undertaking a revamping project, it is important to rely on experienced partners with decades of multi-sector expertise. CD Automation has been manufacturing intelligent electrical power control systems for over thirty years, supporting applications such as plastics and packaging machines, furnaces for heat treatment of glass and metals, the food industry, and renewable and traditional energy systems, including oil and gas.

Revamping: the importance of product reliability

CD Automation produces top-quality thyristor power controllers, supported internationally by a network of branches and leading partners in the industrial temperature control sector. These products help reduce:

• power line disturbances,
• electrical cable heating,
• energy losses.

The control system developed by CD Automation keeps the power factor close to 1, avoiding unnecessary energy costs.
The company also focuses on compact designs by integrating multiple functions into a single multi-channel unit, meeting the demands for compactness, competitiveness, and sustainability.

The ideal unit for every need

CD Automation has established a centre of expertise to support partners in electrifying applications, reducing consumption and complexity, and improving power quality in thermal processes.
Companies can draw on a wide range of products, including SCR units such as:

• REVO S – High-performance, reliable, flexible and compact solid state relays, available from 3.5 to 800A.
• REVEX – Universal power regulators with flexible configuration and high performance.
• REVO C – Universal single/two/three-phase power controller from 30 to 2100A.
• REVO PN and REVO PC – Multi-channel power controllers for intelligent management of electrical loads.

Are you planning to update your heating systems or undertake a revamping project and need the expert advice of a professional? Contact us to schedule a free consultation with one of our specialists. You will receive tailored proposals to optimise your systems, extend their lifespan, and minimise downtime. 

Float glass: definition and history

The name float glass (from the English “to float”) refers to the flotation system with which the material is manufactured, in particular to the stage of the process in which the molten glass ribbon, coming out of the furnace, floats on top of a layer of tin (the float bath), in a controlled atmosphere. The process, which has been in place since the 1950s, makes it possible to produce glass sheets that find numerous uses in the construction industry. The float glass production operation, on a commercial level, was devised by Alastair Pilkington and Kenneth Bickerstaff, with the aim of obtaining flat or smooth glass sheets without resorting to costly operations to eliminate abrasion.

Float glass has quality and strength characteristics that cover a large part of the world’s glass production, thanks to a production process that allows large quantities of material to be processed at low cost. This processing makes it possible to produce products with different colours, perfectly smooth and suitable for various processes, such as decoration, grinding, bending, layering and coking.

Production steps for float glass

The melting furnace

In this process, the raw materials used are:

• a vitrifying agent, i.e. silica sand (70/74%)
• a stabiliser, calcium carbonate (12/13%)
• a flux, sodium sulphate (12/13%).

In the inlet area of these elements, careful temperature control is essential in order to avoid rapid deterioration of the furnace’s firing thermocouples due to the high operating temperatures. Here, the mixture of raw materials, measured and humidified to obtain a vitrifiable substance, is conveyed by conveyor belts into the melting furnace, inside which the temperature reaches 1550°C.

The tin bath

On leaving the melting furnace, the viscous glass is passed over a bath of molten tin at a temperature of around 1000°C. As we anticipate, it floats on the liquid, flat surface and is pulled until it becomes a ribbon with parallel faces. The tin smoothes the lower surface of the glass by direct contact, while the upper part is flattened by gravity, as it is a material in a semi-melted state. On the edges of the belt, toothed wheels (top-rolls) stretch or retract the glass laterally to obtain the desired width and thickness. The thicknesses obtained are between 1.1 and 19 millimetres.

Annealing and controlled cooling

At the end of the tin bath phase, the temperature of the glass is about 600°C. It, now in a solid state, enters an annealing chamber. This process step serves to change the internal tensions of the material to make it more suitable for cutting. The float glass is then lifted and placed in a cooling tunnel, where it reaches room temperature.

The cutting

The ribbon is then cut into standard glass sheets, mostly measuring 6×3.21 metres, with the longitudinal edges removed. At the end of the line, the float glass sheets are positioned vertically on the backs by means of suction lifts.

CD Automation solutions for float glass production

This brief overview of the float glass production process makes clear the strategic importance of precise power and temperature control throughout the various processing stages. For this reason, equipping float glass production lines with top-quality SCR power controllers is one of the priority missions of CD Automation’s technical department, which has been studying processes for over thirty years in order to define the most suitable complete hardware and software system for each requirement.

And the company, based in Legnano, specialises in this application. It provides complete cabinet and thyristor unit solutions and first-class service throughout the life of the float glass production plant.
Typically, the system can have 30 to 35 zones, with a power range from 100 to 150 kW. For each zone it is possible to have a dedicated terminal to be positioned in front of the panel, connected directly to the unit. In the event of an emergency, the unit can be operated by setting the power in manual mode, after knowing the password or enabling it from the control room.

CD Automation’s static units make it possible to regulate the power of applications involved in the production of float glass that make use of heating elements and in particular: silicon carbide elements in the Tin Bath stage and normal three-phase connection resistors in the annealing and controlled cooling stage.

Monitoring of silicon carbide elements

Silicon carbide is a semiconductor material that has a much higher resistivity than metallic materials. The resistance value of these elements at room temperature is quite high, and drops with increasing temperature to a minimum value of approximately 600-900°C. Constant power regulation with a V to VxI transfer is therefore necessary. On three-phase loads with Silicon Carbide, the use of a VxI feedback is suggested to achieve constant power regulation. This is necessary to compensate for changes in the resistance value with temperature and age of the elements. The value at the end of their use is in fact four times the initial value.

REVO C power controllers for more efficient float glass production

The REVO C Series is the ideal solution for regulating power in this application involving silicon carbide elements. This high-performance unit, developed by CD Automation, is adaptable to all SCR applications, including inductive loads, high-temperature oven resistors, infrared or UV ovens. The REVO C SCR is equipped with an advanced microprocessor that makes it universal and fully configurable via software.
REVO C is the most complete unit thanks to:

• three-phase synchronisation, phase rotation diagnostics, phase angle firing, current limit, measurement accuracy;
• integrated Profinet communication and reduced integration time with TIA PORTAL libraries. IP Ethernet communication with libraries for reduced integration time;
• SCCR approval 100kA – 600V (Short Circuit Current Rating), according to UL508.

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Resistance control with the CD Automation Revo S SCR unit

Considering instead the annealing and controlled cooling of float glass, the REVO S Family up to 700A is used for applications with low-variation resistors. Where the REVO S Family consists of high-performance, reliable, flexible and compact SSRs with the following properties:

• nominal voltage 480V-600V-690V;
• SSR or analogue input already configured;
• Burst Firing (Fast Zero Crossing);
• Heater Break alarm to diagnose partial or total load failure or thyristor short circuit;
• internal fuses that reduce wiring time and cabinet size.

Discover the complete catalogue

Above 700A, however, it is necessary to resort to the REVO C Series, which reaches 2100A. The latter is also appreciated for the availability of serial communication and voltage control, which prevents mains voltage fluctuations. For energy savings, the REVO PC Series should be used instead.

In applications involving transformers with loads placed on the secondary, the main requirement is to prevent current peaks occurring when switching on the primary from damaging fuses or thyristors. The REVO C series, with current limit option, has been designed to provide different solutions for driving single-phase transformers. REVO C-3PH, on the other hand, has been designed to drive three-phase transformers.

You want to understand in more detail how REVO C and REVO S can make your float glass production lines more efficient and competitive? Contact us and book a free consultation session with one of our experts.

The global glass industry is constantly evolving, and leading companies are seeking cutting-edge solutions to improve the precision and efficiency of their production processes. As we look ahead to Glasstech 2024, the world’s leading trade fair for glass production, there’s no better time to explore how CD Automation’s thyristor units are driving innovation in this sector. Our solutions, designed for optimal control of energy and temperature, are playing a key role in supporting the glass industry’s push toward higher efficiency and sustainability.

Hot topic of Glasstec

Glasstec qualifies as the largest global stage for the glass industry, where the five topics crucial for the development and success of the entire industry, which is facing a complicated economic situation, were discussed. Specifically, the main topics are:

• Climate → emissions reduction and renewable energies;
• Urbanism → glass in the architecture of the future;
• Value → sustainable value chain;
• Resources → efficient and sustainable use of resources;
• Well-being → a better quality of life thanks to glass.

Solutions for float glass processing

These macro-trends, particularly those relating to climate and resources, are a priority for CD Automation’s technical department, which is called upon to study the processes involved in the glass production lines, define the complete system of hardware and software required, carry out the start-up and provide first-class service throughout the life of the plants.

Let us now look in detail at CD Automation’s offer and applications for the glass industry, starting with the production of float glass.
This process involves the transit of the molten glass ribbon as it exits the furnace, over a bath of liquid tin, the float bath, from which the product takes its name. CD Automation offers SCR units for float and annealing glass production lines. This is the typical cycle for the glass industry, with Profinet/ Ethernet IP, Modbus TCP communication.

CD Automation offers

Usually, the system can have 30 to 35 zones, each zone with a power range from 100 to 150 KW. The product recommended by CD Automation for this application is the REVO C-3PH. For each zone, it is possible to have a dedicated terminal to be positioned in front of the panel, connected directly to the unit. In case of emergency, the unit can be operated by setting its power in manual mode. In the Tin Bath part, the silicon carbide elements are placed on the secondary side of a transformer, while the REVO C and REVO S 2PH series are used to control the normal three-phase connected resistors in the Annealing Lehr part. In addition, the company supplies REVO PC: this high-performance unit, with its special algorithm, reduces energy costs, synchronisation and power limits for each zone.

CD Automation, with its decades of experience, also supports the glass industry in the following applications:

• Boosting Power Control,
• Tin Furnace Power Control,
• Power Control of Continuous Annealing Furnace.

Solutions for glass tempering plants

The Legnano-based company’s expertise is not limited to float glass production lines. CD Automation’s SCR units are, in fact, the winning allies for glass tempering systems, a heat treatment that aims to put the surface layer of the material under compression to improve its resistance to breakage and minimise personal injury, in case of glass damage. Static units are used in the glass heating part of the process. Among the most widely used products are the REVO S series, with logic input, load and SCR diagnostics, and theREVEX, REVO C and REVO PC series, which allow more data on process variables through fieldbus.

Solutions for glass laminating and bending plants

Together with the glass tempering process, the lamination process takes place, which consists of joining several layers of glass with a plastic film. This process prevents glass fragments from detaching from the plastic film in case of breakage. Also linked to this process in the glass industry are those of bending and screen printing.
With the thermal tempering process, the bending furnace is heated to temperatures between 650 and 750°C to obtain a sufficiently viscous sheet, which is adhered to a concave or convex mould positioned inside the machine. A cooling phase follows, in which the glass remains compressed in the mould.
This is a process where the precision required in power control must be very high. This process therefore requires units capable of very accurate power control in either phase angle, single or half cycle load firing modes. We therefore recommend the use of REVEX, REVO C or REVO PN units.

The list of heating elements

CD Automation’s static units can regulate power in the following glass industry applications using heating elements:

• Silicon carbide elements. A semiconductor material with a much higher resistivity than metallic materials. Elements made of this material characterise electric convection furnaces, laboratory melting furnaces (with temperatures up to 1500°C), glass fusing furnaces (up to 1350°C) and float glass manufacture.
• Kanthal Super elements. These resistors change with temperature, but do not change with age, compared to their predecessors, and are used in high-temperature furnaces (1600°C to 1800°C).
• Traditional heating elements. They are used in furnaces with radiation or convection heating, continuous furnaces, chamber furnaces, basin furnaces (up to 900°C), glass tempering furnaces, glass annealing furnaces, windshield moulding, auto glass and glass lamination.
• Infrared lamps. In secondary glass industry processing, infrared radiation is used for localised, fast and direct heating. This type of heating has a high penetrative efficiency, requires little cost and is easy to install and maintain. Infrared lamps distinguish furnaces for fusing, decorating, firing float glass and glass decals. But also, glass fusing furnaces (up to 1000°C), glass screen printing drying, glass laminating and tempering processes, solar cell production lines (metallised and diffusion), photovoltaic module production lines (preheating and stringing) and thin film in preheating lines.

Do you work in the glass industry and need tips on how to manage the thermal process efficiently and sustainably? Contact us and book a free consultation session with one of our experts.

Thermoforming: a thermal operation

Thermoforming is a plastic production process that involves heating a sheet of plastic and giving it a specific shape using moulds. The shaped material is then cooled and trimmed to obtain the finished part. The process is carried out using a thermoforming machine that heats and stretches the plastic sheet over the mould.

The different thermoforming processes

The most popular thermoforming techniques are as follows:

• Vacuum forming: the plastic sheet is heated and then forced against a mould thanks to the application of vacuum, which makes the sheet perfectly adhere to the mould imitating its form. This type is known for its convenience and speed of the production process.
• Pressure thermoforming: the plastic film is pushed onto the mould by high pressure exerted from the outside by air, which facilitates cooling. Pressure thermoforming is used when a high degree of detail is required.

There are also other thermoforming methods: mechanical, draping, laminated die, double foil and negative die, designed for specific applications and production volumes.

What are the advantages of thermoforming?

Thermoforming allows even very thin thicknesses to be moulded, unlike other plastics processes. In addition, through the production of moulds with numerous footprints/cavities, it makes it possible to reduce production times and to achieve an advantageous balance in the ratio of production costs to the number of parts sufficient to sustain a break-even-point of sufficient or fair economic viability.
Last but not least, thermoforming tooling costs and set-up times are significantly lower than in other processes involving thermoplastics, offering maximum flexibility due to reduced machine set-up times and maximum convenience for the production of small quantities of thermoformed parts.

Numerous applications

Therefore, thanks to the possibility of using sheets with different thicknesses, surface finishes and colours, thermoforming lends itself to the production of a wide range of artefacts in many areas, including:

• food packaging;
• pharmaceutical packaging;
• medical & hospital sector;
• automotive and transport industry;
• nautical industry;
• electrical and electronics industry;
• building and furnishing.

Two crucial steps: clamping and warming up

The thermoforming process is characterised by two crucial moments for the success of the products: clamping and heating. As far as the first step is concerned, in order for the plastic sheet to be clamped in the most appropriate manner during the moulding process, it is necessary for the clamping frame to have a rather high power. Where the process is automated, it is also necessary to provide a protective casing for the moving parts in operation to prevent any accidental damage.

The elements involved in the heating phase are, on the other hand, generally infrared, installed inside a reflector plate made of aluminium. The sheet to be formed, as described, must be heated to a high temperature. During this process, it is necessary for the heat to be homogeneous over the entire surface and thickness. For this reason, the application requires the use of energy regulators to monitor these heating zones.

Why rely on CD Automation?

CD Automation has been playing a leading role in the control of heating elements for over thirty years. Since 1987, the company has in fact been manufacturing thyristor power units, soft starters and SCR power controllers of the highest quality, and is a leading partner in industrial temperature control.

In addition, CD Automation has created a competence centre to support partners in electrifying applications, reducing complexity and consumption and improving the power quality of thermal processes, according to a sustainability-oriented approach.

Products serving thermoforming

CD Automation has developed, for the efficiency and sustainability of thermoforming processes and the control of heating elements, the REVO PN and REVO PC multi-channel power units, capable of handling applications with many power zones, through a small footprint. Thanks to the power distribution algorithm, with these two units it is possible to balance and limit the peak current demand in order to maintain a high quality of the absorbed current, limiting losses and consumption and avoiding penalties and unforeseen expenses.

A CD Automation summary of benefits

In short, the solutions developed by CD Automation, for customers engaged in thermoforming processes, enable:

• optimising consumption;
• monitoring electrical variables;
• early diagnosis of heating element breaks and short circuits on thyristors;
• communicate via the most common field buses;
• reduce flickering in applications involving short-wave infrared lamps, thanks to the “Dynamic burst firing” mode.

You want to find out how to make your thermoforming processes more efficient and competitive? Contact us and book a free consultation session with one of our experts. You will receive strategic and customised proposals according to your needs.

Introduction to heat treatment

Heat treatment can be defined as a combination of heating and cooling operations to which a metal or alloy in a solid state is subjected in order to obtain the desired conditions and properties. Simplifying as much as possible, a classic heat treatment consists of a temperature raising or heating phase, a temperature holding or holding phase and a cooling down to ambient or cryogenic temperatures.

What are the goals?

Heat treatments can be used to homogenise cast metal alloys, to improve their hot workability, to soften metals before and during hot and cold working operations, or to alter their microstructure in order to achieve the desired mechanical properties.
Heat treatments of metal alloys are also used to modify the surface chemical structure of materials. This modification is generated through the diffusion of carbon, nitrogen and other gaseous or solid materials onto the surface of the component. These processes are used to give a certain surface hardness and to increase wear, corrosion and stress resistance.

The parameters involved

In order to choose the most appropriate heat treatment process and to make operations more efficient, several parameters should be taken into account, including:

• Type of alloy;
• Heating and cooling requirements;
• Work input;
• Time;
• Atmosphere;
• Surface plating;
• Surface diffusion.

In order for metal components to be suitable for their intended purpose, it may be necessary to subject them to a series of conditioning and finishing treatments, performed to ensure that the combination required by these parameters is precisely controlled in order to obtain the desired component.

Treatments are performed in furnaces where gases are used to control the process atmosphere. Controlled atmospheres are used to reduce the effects of oxidation or to provide an enriched atmosphere for surface chemical effects on the component undergoing the operation.

Heat-treatment methods

According to their purpose, heat treatment operations are subdivided into:

• General treatments. These include: homogenisation → performed prior to hot working processes with the aim of equalising the temperature of an alloy or reducing the micro-segregation effect due to non-uniform chemical composition.
  Annealing → includes various heat treatment processes aimed at softening alloys and increasing their ductility prior to cold working.
  Normalisation/ distension → performed in order to eliminate internal stresses in welded, cast or rapidly cooled components.

• Treatments which change the phase structure of an alloy. These include hardening → this is achieved by heating an alloy to a predefined temperature and then tempering it in oil, water, air or using a special polymer quench.
  Tempering → generally follows the hardening process in order to remove much of the acquired brittleness from the alloy, while retaining the hardness of the components.
  Induction hardening → rapid heating with an induction coil is immediately followed by a hardening process to harden the metal alloy. Alternatively, this same process can be performed by direct contact with an incandescent flame or by laser heating techniques.

• Treatments which change the surface chemical structure of an alloy. In carburizing, nitriding, carbonitriding and nitrocarburizing processes, the surface layers of the alloy are hardened and tempered by exposing the component to a carbon or nitrogen enriched gaseous atmosphere, while the material is subjected to a high heat profile prior to tempering.

• Other specialised processes include hot isostatic pressure (HIP ping) → used for the densification of castings and pre-synthesised components and in diffusion welding of alloys. It requires extremely high temperatures and pressures in a specially designed vessel.
  Sintering → Many products with complex cross-sectional shapes are obtained from powdered base materials pressed or moulded into the shape of the component. Sintering takes place in a controlled atmosphere environment and is used to strengthen the bond of compacted powder components in a process cycle with set times and temperatures.

Why use CD Automation’s know-how?

As can be deduced from this overview, the different types of heat treatment require advanced knowledge in the fields of thermotechnics and materials science. For this reason, and in order to make metal heat treatment processes efficient and sustainable, it is essential to turn to reliable partners with decades of know-how. This is the case with CD Automation, a company that for over thirty years has been producing intelligent systems for controlling electrical power via static contactors and industrial temperature controllers for metal and glass heat treatment furnaces and for: plastics machinery, packaging, the food industry, Oil & Gas and systems for managing renewable and traditional energies.

Different solutions for multiple benefits

More specifically, the company manufactures thyristor power units and soft starters of the highest quality, with the support of an international system of subsidiaries and partners of primary importance in the industrial thermoregulation sector. Through these products, the company guarantees the reduction of:

• Disturbances on the power supply line,
• Heating of electrical cables,
• Energy losses.

 
The control system designed by CD Automation makes it possible to maintain Power Factor values close to 1 and avoid energy cost penalties. Last but not least, the company is committed to reducing the size of the control panel by integrating several functions in a single multi-channel unit, thus meeting the requirements of compactness, competitiveness and sustainability of processes and products.

Introducing the REVO C 3PH unit

Specifically for metal heat treatment processes, CD Automation has produced the REVO C 3PH universal power controller: a high-performance unit, adaptable to all SCR applications, including inductive loads, high-temperature furnace resistors, infrared or UV furnaces.
REVO C 3PH is equipped with an advanced microprocessor that makes it universal and fully configurable via software. The unit also proves to be an indispensable tool in Industry 4.0, thanks to its Ethernet IP and integrated Profinet communication, with libraries to reduce integration time.

Technical features

REVO C is the most complete unit ever because of its three-phase synchronisation, phase angle switching, measurement accuracy and current limit. In fact, the three-phase power controller has:

• Universal inputs: Analogue 4:20mA / 0:10V and SSR input configurable via software.
• Current range from 30 to 2100A.
• Voltage ranges 480V, 600V and 690V +/-10%.
• OLED Display, providing optimal operator vision and user-friendly messages.
• Powerful diagnostics, with clear messages in the event of an alarm.
• All firing types come standard: Zero Cross, Half Cycle, Single Cycle, Burst Firing, Delayed Triggering, Phase Angle and Soft Start.
• Universal Control Mode/strong>: can be configured with feedback on Current, Voltage, Power or in Open Loop mode.
• Data logging Integrated on SD memory card with programmable storage intervals
• High-precision measurement (True RMS Value per V, I e VxI) =< 1%
• Integrated fuses with quick and easy access allow for reduced cabinet space and more efficient heat dissipation.
• High short circuit protection: 100 KA Short Circuit Current rating (SCCR) up to 600V. Oversizing of Thyristors and parts subjected to temperature with the use of high efficiency heat exchangers.
• USB port on the front of the unit allows the REVO C to be configured easily and safely as the unit is powered by the USB port itself.
• Integrated signal analyser for faster and easier identification of process problems.

Would you like to find out how to make your metal heat treatment processes more efficient and competitive? Contact us us and book a free consultation session with one of our experts. You will receive strategic proposals customised to your needs.