Case studies

Vooban has developed a predictive artificial intelligence model to optimize production line operations. The model automatically manages the flow of material fed to the shredder, stabilizing the supply based on its predicted quantity at the end of the line within a given timeframe. This ensures a constant outgoing material flow, optimizing production without endangering the machines. As a result, the operator no longer needs to monitor this component.

Vooban has also designed a predictive maintenance system for shredder knives that considers their lifespan, production goals, and the types of materials to be processed. Using an operational research model, the system determines which knife to use to achieve the best production outcome according to its condition and the production requirements. This approach optimizes maintenance and minimizes downtime as much as possible..

The project enabled the company to increase the hourly productivity of their recycling line by 40%, reaching a production rate of 3.74 tons of recycled plastic per hour (without production stoppages), compared to 2.67 tons/hour previously. Additionally, production processes have become consistent across operators, making it easier to identify the causes of lower performance since it no longer depends on human factors. The instances of unplanned stoppages resulting from breakages, blockages, or other issues has decreased by more than 50%.

Vooban’s work on predictive maintenance for the knives allowed the company to achieve much more stable production, as the right knives with the appropriate degree of wear for the required production were always in place.

The project improved the company’s competitiveness in the market by ensuring high-quality production volumes at competitive costs, while also reducing their reliance on labor in the context of a labor shortage.