Cosmetics Production at Beiersdorfer (Germany)

Beiersdorf produces brand name articles, and is a globally-active company. It most famous brands are Nivea, Hansaplast and Tesa. These innovative brands are recognized world-wide, and represent the core competencies: skin care, care of wounds and adhesive technology. Powerful production and transportation facilities are necessary and only state-of-the-art production facilities guarantee that Beiersdorf can always supply products in proven high quality. Reliable production can only be guaranteed by state-of-the-art logistics and warehouse technology. Therefore, the cosmetics manufacturer decided to modernize its raw material warehouse. using PROFIBUS DP and WinBloc I/O modules. Using a shelf operator terminal, which covers more than 3500 storage locations, raw materials and supplies are available for the production of cosmetic products.

For this reason, Beiersdorf decided to fundamentally modernize the raw materials warehouse for its cosmed division. In place of the "manual" high-bay warehouse with two shelf operator-terminals (RGB), a modernized high-bay warehouse has been integrated into the building. This system, operated via a shelf-operator terminal, covers 3650 storage locations, and directly supplies the well-known blue-white tubs, as well as raw materials and supplies to the filling locations. A Siemens S5-135 U as well as a PROFIBUS DP interface module control the individual segments of the logistics with a baud rate of 1.5 Mbaud. WinBloc I/O modules are remotely positioned along the rolling surfaces. The sensor and actuator signals are fed to the bus via Weidmüller modules and repeaters. At anytime in the day, service personnel can couple into PROFIBUS DP via a handheld terminal without interrupting the process. A text display in each control cabinet also makes operation easy.

PROFIBUS is used throughout the system, from the I/O level right through to the master computer. The wide range of products for PROFIBUS, allows a free choice of supplier and results in savings in hardware and software. Further savings can be made in project planning and set up of the system. Another benefit of this fieldbus system is the ability to individually operate single segments and/or small parts of the network. The latter feature was of particular benefit for the modernization of the raw material warehouse; the points for incoming goods and identification, as well as cream filling, are all on separate levels. During the planning of the new warehouse, the technical facts of the building had to be considered, because large structural modifications were not to be performed. The PROFIBUS concept with I/O modules - requiring minimum space ? exactly meets the requirements.