Toppan Printing: Develops a Set of DX Solutions for Environmental Preservation Activities in Factories |
Tokyo – June 20, 2022 – Toppan (TYO: 7911), a global leader in communications, security, packaging, decorative materials and electronics solutions, has developed e-Platch™, an integrated monitoring system that can improve overall risk management at manufacturing plants by automatically collecting environmental data, such as effluent water level and hydrogen ion concentration.
Features of e-Platch™, a set of DX solutions for environmental conservation activities in manufacturing plants
© Toppan Inc.
e-Platch is a packaged solution based on the automated environmental data collection system that Toppan implemented in its own factories in October 2021. Taking advantage of ZETA,1 a next-generation LPWA (Low Power Wide Area) network protocol, Toppan created an automated system using existing measurement instruments on a zero-blind spot ZETA network and introduced it to its own factories. Integrated monitoring, including environmental data analysis and reporting, is now possible with the addition of an automated remote reading function for analog needle meters and a dedicated monitoring application. The system can improve efficiency and reduce the workload for environmental conservation and inspection work in factories and facilities and enable human resources to be allocated to more active conservation activities.
e-Platch will be exhibited in the Toppan corner of the ZETA Alliance booth (3-6, West Hall 1) during the Local 5G/IoT Service Expo, which will be held at Tokyo Big Sight Expo Center from June 29 to July 1.
Efforts to tackle climate change and other global environmental issues are now essential to business survival. Given the need to contribute to the achievement of the SDGs, the preservation of the environment at manufacturing sites in particular is a corporate social responsibility. However, it has been difficult to take advantage of the Internet of Things (IoT) using conventional network technologies in many factories because measuring instruments and sensors are often installed in indoor or underground locations. with poor signal reception or in outdoor areas with limited access to power sources. Other challenges to take advantage of the IoT include the human workload to collect environmental data from measuring instruments or sensors and, in particular, to physically read analog needle meters. The investment required to switch to digital meters presents another obstacle.
Toppan, backed by its ZETA communications expertise, has brought its technology and expertise to a collaboration with Alps Alpine Co., Ltd. (Alps Alpine), a company with advanced technical capabilities and extensive experience in electronic components and in-vehicle information. devices. The two companies have made possible the use on a ZETA network of automated remote reading devices fitted to existing analogue needle meters.
A zero-blind spot ZETA network, data converters that use existing metering instruments, and automated remote reading of analog needle meters combine to remove barriers to using IoT for environmental data monitoring. Moreover, the integration and visualization on a dedicated application offers an end-to-end solution for the digital transformation (DX) of environmental conservation. Toppan can also provide an interface with its NAVINECT® DX manufacturing support solution via ZETADRIVE®which collects and manages various data obtained on a ZETA network.
“e-Platch is an ideal solution for customers who face challenges in environmental data collection,” said Yoshihisa Aida, general manager of marketing for Toppan’s electronics division. “We believe it brings significant value to manufacturing operations by providing innovative new ways to reduce human workload using a ZETA network that can cover all areas of a factory, but without requiring the replacement of existing instruments.”
Features of e-Platch™
Wireless network without blind spot based on ZETA
Many manufacturing plants have areas with complex structures that prevent signal transmission or locations where it is difficult to secure a power source. Appropriate placement of battery-powered intermediate nodes, called motes, enables a wireless network without blind spots.
The ZETABOX™ data converter facilitates the use of existing measuring instruments
The ZETABOX™ data converter allows data from measuring instruments to be digitized and sent to a ZETA network. Because existing measuring instruments can be used, initial costs are reduced and data collection does not require changes in the way maintenance and related tasks are performed.
Toppan’s solution uses an analog meter monitoring system from Alps Alpine.
© Alps Alpine Co., Ltd.
The workload required to physically verify multiple analog needle meters inside a plant can be reduced with automated remote reading, achieved by connecting to the IoT-based solution for analog meter monitoring developed by Alps Alpine. A ZETA-compliant system was created by combining Toppan’s strengths in developing solutions leveraging digital technologies with Alps Alpine’s device and software capabilities.
The movement of a specially designed magnetic mount attached to the speedometer needle is measured by a magnetic sensor, and the angle is communicated to a cloud server by ZETA technology. The counter values are then calculated and made visible on the dedicated application. It also allows remote monitoring of readings at low cost as the device can be attached to already installed meters. A significant advantage of this solution is the high level of accuracy it offers as it is little affected by external conditions, such as shadows from covers or insufficient light, which can be problematic for current camera-based techniques. which are widely used.
Dedicated e-Platch monitoring app to visualize environmental conservation activities
The data collected by the sensors is managed on the cloud-based ZETADRIVE platform. Through an Application Programming Interface (API) with a dedicated monitoring application, the data can then be used for analysis, charting, alerting functions, reporting, and other outputs to provide full visibility for environmental conservation work.
Link with NAVINECT for manufacturing DX support
NAVINECT is Toppan’s solution to support the digital transformation of manufacturing operations. Manufacturing line monitoring options can be greatly increased by connecting to NAVINECT via ZETADRIVE.
NAVINECT website: https://navinect.jp/ (Japanese)
About 5G/IoT Local Services Exhibition
Dates: June 29 to July 1, 2022
Hours: 10 a.m.-6 p.m. (10 a.m.-5 p.m. on the last day)
Location: Tokyo Big Sight, West Hall 1, Booth 3-6
Organizer: RX Japan Ltd.
1. ZETA is the latest LPWA network protocol designed for IoT. It was developed by ZiFiSense and features ultra-narrow band (UNB), distributed access with smart mesh topology and two-way communication. ZETA draws attention to its ability to operate at lower cost and with fewer base stations than other LPWA protocols due to multi-hop communication via motes.
Established in Tokyo in 1900, Toppan is a leading and diversified global supplier committed to providing sustainable and integrated solutions in areas such as printing, communications, security, packaging, decorative materials, electronics and digital transformation. Toppan’s global team of more than 50,000 employees delivers optimal solutions enabled by industry-leading expertise and technology to meet the diverse challenges of every industry and society and help achieve future goals. shared sustainable development goals.
For more information, visit https://www.toppan.com/en/ or follow Toppan on LinkedIn https://www.linkedin.com/company/toppan/.