Rethinking control systems
Innovative control solutions for efficiency, transparency, and future-readiness
The demands placed on modern production processes in polyurethane processing are steadily increasing. Energy and raw material savings, digital integration, and full transparency are becoming critical factors for economic success. Amid this interplay of efficiency pressure, sustainability targets, and digitalization, Hennecke is setting new standards with its two new control systems: FOAMATIC and FOAMWARE.
As central components of the group-wide digital strategy, FOAMATIC and FOAMWARE form the technological foundation for the intelligent control, analysis, and optimization of machines and systems. Both solutions include equipment features that make an active contribution to conserving resources, increasing efficiency, and improving process quality – all in the spirit of sustainable, future-ready production.
Why new control systems?
Hennecke’s previous control systems – WINTRONIC, PDE, and PURTRONIC – provided reliable process solutions for many years. But the requirements of today’s industrial production go far beyond this. The underlying IT architectures – based on outdated Microsoft systems, for example – are no longer suitable for reliably supporting and further developing modern functions such as remote access, real-time data analysis, or predictive maintenance. “We have completely rethought the control logic from scratch, focusing on the requirements of our customers,” explains Alexander Peters, Director Engineering & Development. The development followed the principles of practicality, efficiency, and openness to integration. The result is two modular control solutions that not only optimally equip new systems and machines, but – especially in the case of FOAMWARE – are also ideally suited for modernizing existing systems. Both FOAMATIC and FOAMWARE enable end-to-end digitalization and ensure smooth operation across all stages of PUR production.
Platform overview: FOAMATIC and FOAMWARE
With FOAMATIC and FOAMWARE, Hennecke is introducing two independent platforms that address different production requirements but are based on a common system concept. While FOAMATIC is used as a programmable logic control at the machine level both for current metering machines and other system technology, FOAMWARE is aimed at complex system structures with high data volumes. The PC-based solution offers maximum transparency and control depth in continuous and discontinuous processes.
Both platforms support the highest IT security standards thanks to a modern system architecture, as well as significant energy savings, reduced raw material consumption, and lower pressure losses. They allow more precise and faster processes, feature modern, graphically guided user interfaces, and integrate functions such as stand-by timers and pump and temperature control. Both systems support predictive maintenance with real-time data and are Industry 4.0-compatible thanks to their open, scalable architecture.
FOAMATIC – Intelligent automation for PLC-based production systems
With FOAMATIC, Hennecke has developed a completely new control solution whose system architecture combines a modern human-machine interface (HMI) with a powerful programmable logic control (PLC). The platform is an integral part of all next-generation metering machines and will be used in other system types in the future. “Our aim was to make central machine functions intuitively operable, exploit energy efficiency potential, and sustainably increase production quality and system availability,” explains Peters. The HMI impresses with an intuitive, graphically guided interface that visualizes all process statuses in real time. Clear user guidance and visual feedback reduce operator errors and enable fast parameter adjustments. A key element here is the “three-click philosophy”: All functions can be accessed with a maximum of three clicks – making operation simple and intuitive. Shortcuts and WiFi connectivity in particular enable unprecedented control options thanks to faster and, in some cases, location-independent inputs. In the background, the PLC ensures rapid response, high reliability, and seamless integration into existing production environments.
Advantages of the FOAMATIC control system
- Improved energy efficiency through optimized control logic
- Raw material savings thanks to more precise metering processes based on advanced control technology
- Increased production quality and process stability
- Faster commissioning thanks to simplified user guidance
- Optimal preparation for digital services and remote maintenance
- Ready for Industry 4.0 thanks to expandable system architecture
FOAMATIC-IOT free trial
Metering machines such as the HIGHLINE MK2 or TOPLINE MK2 are IoT-ready as standard. Hennecke currently offers a six-month free trial with full functionality – including all presently available IoT features.
Cloud-based extension for greater efficiency: FOAMATIC-IoT
With FOAMATIC-IoT, Hennecke is expanding its control technology with a powerful cloud solution for recording, analyzing, and visualizing process-relevant data. The platform provides an unprecedented level of transparency in PUR production – from consumption monitoring to predictive maintenance. Production data is collected, stored, and intelligently evaluated in real time. This makes it possible to identify potential savings in raw materials and energy as well as deviations in the production process or impending malfunctions.
The system is IoT-ready as standard: Connection is via secure network interfaces. The browser-based dashboard is accessible to FOAMATIC-IoT customers worldwide on all internet-enabled devices. It visually displays current and historical production data, allows comparisons, and provides concrete recommendations for action – whether for maintenance planning, optimizing system availability, or based on shot-data acquisition via an indicator system. Optional push notifications automatically inform users of system events.
Special emphasis has also been placed on data security: All information is stored in compliance with European GDPR laws on a certified infrastructure of a German cloud provider, and customers retain full control over their data at all times. FOAMATIC-IoT is not only future-ready, but is already prepared for the use of AI-supported analysis methods. Thanks to standard hardware integration in the Hennecke NEXT-GEN metering machines, the digital functionality can be activated at any time.
FOAMWARE – Comprehensive process control for complex requirements
FOAMWARE is Hennecke’s modular control solution for industrial manufacturing processes on larger production systems with large data volumes and high demands on integration and flexibility. The software was also developed from the ground up and builds on decades of experience in PUR process control. While it is designed primarily for applications in slabstock and molded foam production, its modular structure keeps it open for additional application fields in the future.
The platform offers precise control and analysis of production processes in real time. An extensive range of features is included as standard: Flow charts, process charts, and a calibration manager ensure maximum transparency. Process deviations are detected immediately, stable production processes are ensured, and all relevant parameters are centrally documented. A flexible plug-in concept is also available – for example, for Hennecke Process Analysis (HPA) or a Web Service Module for mobile monitoring. The integration of an optional third-party interface also enables bidirectional connectivity with ERP, MES, or other IT systems – ensuring seamless embedding into digital production architectures.
“FOAMWARE is also ideally suited as a retrofit solution,” adds Mahmoud Karime, Senior Director Global Service. “This not only provides users of older systems with a future-proof IT-compliant control level, but also significantly higher process reliability combined with increased efficiency and a sustainable IT infrastructure.”
Technical equipment
- State-of-the-art hardware for maximum operational reliability
- High-performance SIMATIC quad-core industrial PC
- 32-inch UHD monitor, optional expansion available
- Ergonomic control panel
- Uninterruptible power supply
- Air conditioning
- Integrated printing solution
- Remote-access router for online support
Precision and process stability for slabstock foam production
FOAMWARE Slabstock was developed specifically for continuous slabstock foam production and is optimally adapted to the requirements of modern polyurethane processing. As an application-specific version of the modular FOAMWARE platform, it offers a highly stable control environment that ensures consistently high production quality even under varying conditions – such as fluctuations in temperature or raw materials.
The software architecture enables the precise control of complex reaction processes and creates the basis for uniform material distribution, reproducible foam heights, and reduced reject rates. Thanks to its compatibility with additional measuring and control systems, the functionality can be flexibly expanded: For example, the platform is prepared for the integration of the optional RISE PROFILE MEASUREMENT sensor system, which records the foam height at up to 30 measuring points during the rise process, enabling optimal density distribution.
The AUTO-FLAT system for automated generation of flat foam surfaces can also be integrated. The “Magic Eye” function detects metering deviations during operation and enables immediate intervention. Supplementary software elements such as the Layout Manager or individually configurable quick links ensure intuitive operation, even during operation.
Specialized for automated molded foam production
With FOAMWARE Molded Foam, Hennecke offers a tailored control solution for molded foam systems in which polyurethane is introduced into molds in precisely defined metering cycles. The software was specifically designed for highly automated applications in rotary table systems or oval conveyor plants with variable mold allocation.
The control system supports complex production processes with varying cycle times, output volumes, and process stages, enabling precise and economical production even with high variance. A central function is the integrated shot pattern management, which allows recurring metering sequences to be configured by time, quantity, and mold. Thanks to the flow chart-based visualization of the systems, operators always maintain an overview of ongoing processes.
A particular highlight is the Robot Module, which enables travel paths to be created and edited directly within the software. The part tracking function documents the number of pieces produced per mold in real time and automatically switches off the respective position as soon as the planned quantity has been reached. Empty cycles or downtime intervals can also be scheduled in advance without risking material loss.
All in all, FOAMWARE Molded Foam enables fast, intuitive commissioning, reduces training requirements, and ensures high system efficiency with minimal raw material consumption. Targeted process guidance allows capacities to be used efficiently and significantly increases the overall cost-effectiveness of automated molded foam systems.
Ongoing development for future requirements
With FOAMATIC and FOAMWARE, Hennecke has laid the foundation for a new generation of control technologies. Both platforms embody consistent customer orientation, sustainable efficiency gains, and a sophisticated, expandable modular digitalization solution. “Our control systems grow with the requirements of our customers. As part of our strategic development, we are working closely with users and consistently developing our systems with a view to future requirements in industrial PUR production,” concludes Peters.
