Automation and supervision of the leather making process: The present and future of leather processing technology

Giulio Galiotto.

Introduction
The leather processing industry is constantly evolving, thanks to the introduction of innovative technologies and advanced software solutions that are gradually taking it to ever more advanced automation horizons. One of the leading companies in this evolutionary process is Erretre, which for almost 50 years has been developing innovative machines and systems for leather processing, dedicated to the finishing stages.

Founded in 1974 as a technical studio with the aim of developing new ideas in leather processing, since 1993 the company's technological focus has been on the development of hardware and software systems for data acquisition, tracking, analysis and production documentation, in addition to machine construction, with the ultimate aim of quality and repeatability.

In 1993, the company equipped its machines with its own printed circuit boards, paving the way for automatic and digital data acquisition.

In 1984, in collaboration with the University of Occupational Medicine of Padua, studies were completed on the elimination of aerosols generated during the pigmentation phase of leather, leading to the creation of innovative spraying and pollutants elimination systems that anticipated legal requirements by about 10 years.

In 1992, Erretre introduced a new model of dust collector: the CT2, the forerunner of the current CT7, was the first dust collector with automatic control. In spite of still being electromechanical, It represented an important innovation, guaranteeing optimal filtration of dust and chemical residues and increasing the eco-sustainability of the leather making process.

Automation in the tanning sector: Erretre's technological contribution
Automation in leather processing, software solutions and synergy with partner companies in the Italtannery project, are the cardinal points of the company's vision. It aims at creating an increasingly efficient, eco-sustainable and networked future for tanneries, in which an integral monitoring system will link all the machines involved, guaranteeing precise control and optimised management of the processes.

Erretre has been one of the pioneers in the adoption of 4.0 technologies, developing hardware and software solutions to collect and analyse a huge amount of data from machines.

Always aiming for maximum quality, Erretre equips its technologies, such as milling drums or finishing spray lines, with increasingly precise and user-friendly automation: the introduction of automatic hide unloading systems in 1994 made it possible to automate a critical phase of the process due to the risks associated with manual handling of the workpiece.

A further step forward in process automation was the introduction of the first computerised control panel in 1998, which allowed the operator to control the basic production parameters via digital commands.

Thanks to this deep-rooted experience and continuous research, the machines and software developed by Erretre are both advanced – guaranteeing high precision performance – and accessible to less experienced operators. Expertise and analytical skills act as a filter, an interpreter of the complex languages that control the machines, making the automation accessible to the less experienced operator, allowing him to make the most of the technology in a simple and intuitive way.

Software implementation: the real heart of Erretre machines.
LCAS - Leather Crafting Automation Software - and M.O.Re - Milling Organisational Resources -
The Leather Crafting Automation Software (LCAS), an advanced version of the original software created by Erretre in 2009 under the name of Milling Process Control, operates and manages Erretre's main machines and equipment in an advanced way. This platform makes it possible to visualise the process graphically in real time, to create customised recipes, to manage the various machining variables and to analyse and optimise the results. The HMI (Human Machine Interface) has an intuitive interface that allows the operator to monitor process progress, analyse consumption, view historical data and receive notifications in the event of anomalies, discrepancies or problems, even remotely.

Thanks to the LCAS software, Erretre is able to collect and analyse a wide range of data, including recipe parameters, batch data processed, machine-specific settings, environmental variables, access levels and much more.

Communication is a strong point of the software: Erretre uses a SQL (Structured Query Language) database to facilitate data exchange with the outside world, making data sharing simple and effective. The LCAS software is set up to automatically receive work recipes sent by the customer's management system or MES, ensuring a direct and synchronised link between the various stages of the process.

M.O.Re (Milling Organisational Resources), created by Erretre in 2003, is the software specifically designed to improve the management of the milling department. It allows customers to optimise production planning, ensure direct control of each machine and centralise the creation, management and planning of machining operations. By collecting and analysing production data in real time, the software monitors the smooth running of the entire plant and provides a detailed report on its productivity.

The present of leather processing: Artificial Intelligence for process optimisation
The use of artificial intelligence in the tanning industry is a major step forward. Thanks to sophisticated cognitive algorithms, Erretre's top-of-the-range machines aim at making complex decisions and adjust processing parameters autonomously. This artificial intelligence makes it possible to optimise the production process, further increasing the repeatability of results and minimising waste. For example, AI can adjust the temperature and humidity during the drying process to ensure a consistent, high-quality result. In addition, the historical data collected can be used to predict any problems or anomalies in the process, enabling timely intervention and preventing downtime.

The Future of Tanning: an Artificial Intelligence system that supervises and manages the entire production cycle
The future of tanning is based on a complete monitoring system equipped with artificial intelligence algorithms capable of communicating with all the machines involved in the process. Erretre, together with the other partner companies in the Italtannery project, is working to create an ecosystem of sensors and intelligent systems capable of communicating with each other and optimising the entire production cycle. A real system that, by analysing data from the various stages of the process, will make it possible to track each piece of leather and assess its quality and compliance with the required standards.

The project involves the creation of an integrated monitoring system made up of an array of sensors placed throughout the production chain and an advanced computer system equipped with artificial intelligence capable of analysing the data collected in real time and making autonomous decisions to optimise the processing parameters.

This advanced analysis capability will make it possible to quickly identify any deviations from the ideal process and intervene promptly to maintain high quality standards, opening new possibilities for control and optimisation aimed at achieving unprecedented levels of efficiency and quality.

Conclusions
With automation and artificial intelligence at the heart of the production process, the tanning industry is entering a new era of innovation and competitiveness. Erretre is at the forefront of this transformation, working towards a future where advanced technologies make leather tanning an increasingly sustainable and efficient practice, with top quality results that are repeatable.

Erretre is represented in Southern Africa by Harry E. Teifel & Associates.