ADLER, Austria’s leading manufacturer of varnishes, paints, and wood preservatives, has introduced digital data acquisition for raw materials in its pre-commissioning area, marking a significant step in its digitalisation efforts. Employees in Ex-zone 1/21 now use mobile multifunctional sets from i.safe MOBILE, including the intrinsically safe IS530.1 smartphone and the IS-TH1xx.1 hand-held barcode scanner. These devices enable automatic raw material control during scanning, minimizing errors and reducing faulty batches. The collected data is stored in a database for full traceability, ensuring production transparency and process optimisation. Additionally, hazard warnings and work instructions are integrated into the mobile devices, improving both efficiency and safety.
Seamless Implementation and Increased Efficiency
The barcode scanning system was integrated into ADLER’s existing IT infrastructure with the help of i.safe MOBILE’s partner, ematric, who developed the necessary software. This integration allows for real-time order tracking and ensures accurate recording of each production step, minimizing the risk of overlooked tasks. Initially, there were concerns about workflow disruptions, but the system was implemented smoothly, leading to fewer incorrect batches and improved overall efficiency.
Enhanced Production Control and Quality Assurance
Material traceability is vital in ADLER's production process. The barcode scanning system helps employees quickly identify processed and remaining raw materials. In the pre-commissioning area, up to 1,200 raw materials and semi-finished products are compiled and weighed for each order. Digitalisation enhances quality assurance by preventing material mix-ups and costly mistakes. The IS530.1 smartphone also displays hazard warnings and work instructions, contributing to safety by providing clear visual information to employees for task completion.
Positive Employee Feedback and Future Plans
Employees have responded positively to the digitalisation initiative, resulting in increased job satisfaction. Following training, each worker was equipped with a multifunctional device. QR codes on raw material storage locations and production recipes facilitate quick material identification and help reduce errors. The system alerts employees in case of incorrect scans and shows expiry dates or special processing instructions. The implementation process took about six months from product selection to deployment.
Looking ahead, ADLER plans to extend digitalisation across the entire production process, enabling real-time monitoring. This expansion is part of a broader strategy to increase transparency and responsiveness to customer needs, while integrating insights from the project into future logistics planning. ADLER’s commitment to employee safety and satisfaction ensures that these digitalisation measures will contribute to long-term productivity and innovation.
“The scanners from i.safe MOBILE have truly made a difference,” says foreman Christoph Wolf from ADLER. “With their support, we’ve successfully sped up and simplified our work processes, reducing the error rate. We’ve made significant progress towards digitalisation.”
The Mobile Multifunction Set
With a large reading range of up to 18 metres, the devices are equipped with Zebra OEM imager scan engines for safe mobile data management. At ADLER, the i.safe MOBILE mobile multifunctional set ensures reliable data capture in hazardous areas. This represents a further step towards optimising processes, raising quality standards and ensuring the safety of employees.