Weighing, dosing, mixing, transporting
The integrated solution from fibre opening and conveying through web bonding and finishing all the way to packaging.
proCvlies is flexible and scalable; specific adaptations and extensions can be implemented without difficulty. Its modular design and the use of standard technologies ensure high plant availability and reduce costs for procurement and spare parts.
Your benefits
General benefits
The proCvlies process control system combines control, monitoring, and analytics within a single integrated platform.
It forms the central interface between sensors, actuators, and machine control systems in nonwoven production, ensuring a fully automated and continuous manufacturing process.
This simplifies process standardization, supports recipe reproducibility, and creates a solid foundation for transparency, traceability, and meaningful reporting.
Processes
Our customers benefit from increased efficiency and system availability as well as improved support throughout their manufacturing processes. Secure your decisive competitive advantage.
- Weighing and dosing technology
- Fibre opening
- Fibre blending
- Fibre conveying
- Card feeding
- Web formation
- Web bonding / consolidation
- Winding
- Fibre finishing
Functional Scope
- Recipe Management
- Order Management
- Quality Data Acquisition and Archiving
- Operational Data Acquisition
- Availability Analysis
- Historical Trend Functions
- Fault Logging and Archiving
- Data Traceability
- Maintenance System
Process control system as an integration hub: data flow through to SAP
For vertical integration, proCvlies can be connected to higher-level systems. This can be achieved, for example, with proCMES as the MES layer for production control, detailed scheduling, and KPI generation, as well as for integration with ERP structures. Depending on the project requirements, integration into SAP systems can also be implemented to ensure consistent use of orders, feedback, and relevant production data between planning and production.
This helps reduce interface breaks, avoid duplicate data entry, and establish a reliable data foundation for reporting and quality assurance.
Complementing batch processes
proCbatch
In addition to continuous data flows through to SAP, many plants also include batch-oriented subprocesses. These require clearly defined recipes, set parameters, and accurate feedback data.
proCbatch supports exactly this: a modular batch management system designed for reproducible processes and maximum transparency
Which processes does the proCvlies process control system cover?
Covered process areas:
FIBRE OPENING:
- Control and monitoring of bale opening and fibre openers.
- Early structuring of material feeding to ensure reproducible processes.
FIBRE BLENDING:
- Recording and provision of all blending and material parameters.
- Ensuring consistent data across the entire production process.
VORBPREPARATION (WEIGHING & DOSING):
- Transparent visualization of target vs. actual values.
- Process- and order-related data for stable, quality-oriented operations.
FIBRE CONVEYING:
- Seamless acquisition of all relevant states and events.
- Documentation of process data across multiple plant sections.
WEB LAYING / WEB FORMATION:
- Central operation and monitoring of all process parameters.
- AbsicherungEnsuring process stability through setpoints, trend analysis, and historical data functions.
WEB CONSOLIDATION:
- Structured consolidation of process data, events, and quality information.
- Foundation for Analysis, Documentation, and Quality Verification
WINDING, FINISHING AND PACKAGING:
- Continuous data acquisition through to the finished product.
- Consistent assignment of process and quality data to both order and product.
CONCLUSION:
proCvlies can be used both for individual process sections and as an end-to-end process control system for complete production lines. It provides the foundation for sustainable process optimization and maximum plant performance.
Overview of functionality: process control, data acquisition, and analysis
Core functions at a glance
The proCvlies process control system combines all core functions required for stable process control and traceable documentation in nonwoven production.
Process Control:
- Structured order processing via integrated order management
- Reproducible settings and specifications through recipe management
- Consistent application of process parameters throughout the entire production process
Data Acquisition:
- Real-time online acquisition of operational data
- Continuous process data collection to ensure transparency and traceability
- Additional quality data acquisition depending on production requirements
Analysis and Evaluation:
- Productivity and availability analyses to improve efficiency
- Trend, History, and Profile Functions Evaluation of process behavior over time through trend, historical, and profile analysis functions.
- Integrated alarm and event logging enables fast root cause analysis and supports efficient troubleshooting.
Additional System Functions:
- Archiving and logging functions ensure long-term traceability of all relevant data
- Support for audit requirements and quality documentation
- Manual operation functions for active process control and operator intervention
- Traceability and tracking features for material and production flows
- Integrated warehouse management for end-to-end transparency
- Maintenance and service support to ensure reliable plant operation
From planning to 24/7 service: how we implement proCvlies together
Typical implementation process for proCvlies (scalable depending on project scope):
PLANNING & CONCEPTUAL DESIGN:
Consulting, requirements analysis, functional specification / system specification, component selection, and quotation & implementation planning
ENGINEERING & DEVELOPMENT:
Engineering and implementation of the solution
(e.g. software engineering, data and interface concepts, system integration); if required, also integration of additional automation components
TESTING & ACCEPTANCE:
Verification of the agreed functions and quality (e.g. Factory Acceptance Test (FAT), if applicable)
INSTALLATION & COMMISSIONING:
On-site implementation, commissioning, and functional/safety testing
(e.g. Site Acceptance Test (SAT), if agreed) including documentation
OPERATION, MAINTENANCE & SERVICE:
Support during live operation, maintenance concepts, and optional 24/7 service models (e.g. remote diagnostics, defined response times)
Introducing the proCvlies process control system and increasing efficiency
proCtec GmbH, based in Germany, delivers process control system projects for the international process and manufacturing industry.
Our company has many years of experience in the development, integration, and support of complex automation systems.
As a system partner, proCtec supports customers from initial analysis through to ongoing operation. Through continuous support and further development, industrial operators benefit from long-term planning reliability and future-proof performance across the entire lifecycle of their plants.
FAQ about the Process Control System
proCvlies ist eproCvlies is a process control system for the nonwoven and textile industry. It supports central process control, data acquisition, analysis, and traceability along the entire nonwoven production chain.
