It is from this awareness that SVECOM-P.E. developed the Digital Pressure Control System, a technology designed to bring expanding shafts into the industry 4.0 ecosystem, transforming them into intelligent, monitored and traceable devices.
From reactive management to predictive control
In paper and tissue plants, shafts made of different materials and sizes – steel, aluminum and carbon fiber – are often handled manually by operators. Incorrect pressure settings or improper use can lead to damage, premature wear, and unexpected downtime, directly impacting efficiency and operating costs.
The Digital Pressure Control System makes it possible to move beyond this reactive approach. Each expanding shaft is uniquely identified and continuously monitored: the PLC automatically adjusts machine parameters, reports any anomalies, and records operating cycles and maintenance status. The result is a safer, more controlled and standardized process.
Wireless sensors integrated into the expanding shaft
At the core of the system are industrial wireless sensors installed directly inside the expanding shafts. Thanks to encrypted radio transmission and the absence of wiring, installation is completely plug-and-play, taking only a few seconds and requiring no adapters or connectors.
The sensors, with a protection rating of IP67 or higher, are resistant to shocks, vibrations, oils, acids and alkalis. They offer selectable measurement ranges from 2 up to 1000 bar and can operate at temperatures between -20 °C and +85 °C. The lithium battery life can reach 10–15 years, with over 300 million datapoints per battery – a level of autonomy that drastically reduces maintenance requirements.
Data is collected through an industrial radio receiver and transmitted to an edge gateway unit, which organizes and pre-processes the information before sending it to the PLC or to the dedicated software for analysis. Users can choose whether to integrate the data directly into the machine control circuit or export it to databases and standard formats (SQL, CSV and others) for advanced analysis.
Connectivity and flexibility for every plant
The system is designed to adapt to different plant configurations. The distance between sensor and receiver can reach up to 1 km in optimal conditions, and typically 100–200 meters in industrial environments.
The connection between the receiver and the PLC depends on the fieldbus used: with Profinet, distances of up to 100 meters over copper or up to 14 km via optical fiber can be achieved, while systems such as CAN or RS485 can reach up to 1.2 km.
This flexibility allows integration both on existing lines and on new plants, without requiring invasive modifications.
Tangible benefits for the paper and tissue industries
Adopting the Digital Pressure Control System delivers concrete and measurable advantages:
- Automatic and safe configuration.
- Protection of expanding shafts and components.
- Elimination of machine downtime caused by incorrect settings.
- Reduction of operational stress for operators.
- Process automation.
- Greater sustainability and production traceability.
Constantly monitoring pressure and usage cycles help prevent overloads, enable predictive maintenance planning, and extend the service life of expanding shafts. The result is fewer replacements, reduced material waste and a lower environmental impact.
The expanding shaft becomes a digital asset
In the paper and tissue industry, where efficiency, quality, and operational continuity are critical factors, the digitalization of mechanical components represents a strategic step forward.
With the Digital Pressure Control System, the expanding shaft is no longer just a mechanical component, but a connected asset that generates data, communicates with the machine and actively contributes to optimizing the entire process.
For paper and tissue manufacturers focused on performance, safety and sustainability, digital transformation also starts here: from the intelligence integrated into the elements that every day support and handle the reels, and that today can do much more.
