Functional analysis

Increase production equipment efficiency

Machine safety








Soleno, a major corrugated plastic piping manufacturer, was struggling with a lack of reliability of the 2 corrugators the company depends on in Quebec for the production of 12-inch to 48-inch diameter pipes. Those corrugators are producing continuous piping thanks to a removable mold train propelled by synchronized servomotor-driven axes. The following problems were occurring:

  • No more support from the machine’s manufacturer
  • Closed technology made troubleshooting or third-party improvements impossible
  • No local technical support, leading to major production losses in case of breakdowns
  • Bad servo control of the servomotors causing premature wear of the machine mechanics
  • Reduced operating speed due to bad servo control, causing a decrease of production
  • Dangerous machine putting operators at risk of injury
  • Long setup time when changing mold size
  • Variation in production quality depending on the operator


To address those problems, Lem Technologies worked closely with Soleno to pave the way for a successful modernization:

  • Analysis of the corrugator’s current and desired operation by observing and by discussing with operators, mechanics and production supervisors
  • Validating if the existing mechanics could be reused and suitable for a modernization of the controls
  • Functional description and risk analysis to clearly define the expected outcome of the modernization and to ensure controls are secured
  • Design of a new control panel allowing to achieve the objectives of the modernization without having to change mechanical and drive components
  • Electrical installation of the new panel
  • Programming and start-up


Soleno can take full advantage of its corrugators since the modernization, which has provided the following benefits:

  • Production quality consistency thanks to production recipe management, which automatically adjusts the parameters independently of the operator
  • Elimination of unplanned breakdowns thanks to the reliability of the new control panel
  • Reduction of mechanical wear thanks to the performance of the new servo control
  • Increase of production speed