This awareness led SVECOM-P.E. to develop the Digital 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, expanding shafts of different materials and dimensions – including steel, aluminium and carbon fibre versions – are often handled manually by operators. Incorrect parameter settings or improper use can cause damage, premature wear and unexpected downtime, with a direct impact on efficiency and operating costs.
The Digital Control System makes it possible to move beyond this reactive approach. Each expanding shaft is uniquely identified and continuously monitored: the PLC automatically adjusts the 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 expanding shafts
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, requires only a few seconds and does not need 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 to 1,000 bar and can operate at temperatures between -20°C and +85°C. Lithium battery life can reach 10–15 years, with more than 300 million data points per battery, providing a level of autonomy that drastically reduces maintenance requirements.
The 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 dedicated analysis software. Users can choose whether to integrate the data directly into the machine control system or export it to databases and standard formats, including SQL and CSV, for advanced analysis.
Connectivity and flexibility for every plant
The system is designed to adapt to different plant configurations. The distance between the sensor and receiver can reach up to 1 km under optimal conditions and typically ranges from 100 to 200 metres in industrial environments. The connection between the receiver and the PLC depends on the fieldbus used. With Profinet, distances of up to 100 metres over copper or up to 14 km through optical fibre can be achieved, while systems such as CAN or RS485 can reach up to 1.2 km.
This flexibility allows the system to be integrated into both existing lines and new plants without requiring invasive modifications.
Tangible benefits for the paper and tissue industries
The adoption of the Digital Control System provides concrete and measurable advantages: automatic and safe configuration; protection of expanding shafts and related components; elimination of machine downtime caused by incorrect settings; reduced operational stress for operators; process automation; greater sustainability and production traceability; monitoring of weight, operating cycles, spare-parts lists, pressure and maintenance status of the expanding shafts.
Continuous monitoring of parameters and operating cycles helps prevent overloads, supports predictive maintenance planning and extends the service life of the expanding shafts.
The result is fewer replacements, reduced material waste and a lower environmental impact.
Expanding shafts become digital assets
In the paper and tissue industries, where efficiency, quality and operational continuity are critical factors, the digitalization of mechanical components represents a strategic step forward. With the Digital Control System, expanding shafts are no longer merely mechanical components, but connected assets capable of generating data, communicating with the machine and actively contributing to the optimization of the entire process.
For paper and tissue manufacturers focused on performance, safety and sustainability, digital transformation also begins here: with the intelligence integrated into the components that support and handle reels every day and can now perform a much broader role.
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