#hyppos

HYPPOS, Hyperion Predictive Production Online Software, is an innovative, all-in-one, deep tech, decision-support tool that integrates with production level and business management level IT components of manufacturing plants.

Hyperion has successfully released HYPPOS v.1.0 within the framework of the 2nd Opportunity grant from the Cyprus Research & Innovation Foundation.

Drawing from the HYPPOS-Machine Learning (ML) Smart Sensors project findings, through Project EMBED-Al, Hyperion has been seeking support towards the technological upscale, optimization, demonstration, and exploitation of HYPPOS-AI as an Industry 4.0 solution.

The image below illustrates the HYPPOS completed projects, deliverables, and technical readiness levels:

Hyperion Group is proud to announce that its HYPPOS-related project Embed-AI was selected for funding for by the Cyprus Research & Innovation Foundation within the context of Research in Enterprises (Bridge Programmes).

The main objectives of project EMBED-Al are:

1. Validate the scientific and technical targets of HYPPOS-AI prototype v.2 in an operational environment; and

2. Intensify Hyperion's research and development in AI/ML, and innovation activities.

The Cyprus Institute (CyI) is the participating research partner of Hyperion that will support the project with through its engagement through the technology transfer of AI/ML expertise to Hyperion.

Green polymers, natural polymers & HYPPOS

When it comes to polymers, green and natural aren't the same.

Natural polymers (biopolymers) occur naturally or are produced by living organisms. Natural polymers can be man-made from raw materials found in nature.

Green polymers are produced using green (or sustainable) chemistry. Green chemistry is the design of chemical products and processes that reduce or eliminate the use or creation of substances hazardous to humans and environment. Natural polymers are usually green.

In polymer production, green principles include:

Clean (no-waste) production process.

No use of additional substances (e.g., organic solvents).

High energy efficiency in manufacturing.

Renewable resource and energy usage.

No health and environmental hazards.

High safety standards.

Low carbon footprint.

Controlled product lifecycles with effective waste recycling.

HYPPOS is an integrated, easy-to-configure, fast-to-install, highly compatible, decision support tool for use in continuous and semi-continuous production plants.

HYPPOS already contributes to the above green principles by:

Resulting in a reduction of carbon dioxide emissions.

Reducing resource usage (e.g., energy, water and/or feedstock).

Polymer industry trends predicted to impact manufacturers beyond 2022

1. Sustainability

Original Equipment Manufacturers (OEM) are assuming more responsibility for sustainability by working with suppliers committed to low-waste or zero-waste initiatives and use recycled materials. Manufacturers are tasked with refining processes to include scrap reduction and/or recycling to aid the circular economy, along with introducing earth-friendly resins and additives.

2. Bio-resins & eco-friendly plastic additives

The environmental impact of traditional resins remains under close scrutiny, leading many manufacturers to reconsider their approach to selecting materials. Bio-resins are gaining traction as alternatives since they’re based on natural plant extracts or renewable resources, which aid in green practices through benefits such as safer disposal, energy-efficient manufacturing, and decreased toxic emissions.

3. Reinforced plastics

Carbon, glass, metal, and graphite-reinforced plastics are perhaps most notably embraced by the automotive industry as substitutes for metal components. They are also gaining popularity in medical and defense applications for their low weight, durability, and versatility.

4. Lightweight parts & tools

Given mandates surrounding improved gas mileage in traditional vehicles and longer battery life for hybrids and electric cars, lightweight parts remain a key focus for automotive OEMs. Medical OEMs are seeing shifts in how plastics are used within their industry, largely in concert with advanced technologies.

5. 3D printing & production efficiencies

3D printing is improving many aspects of plastics manufacturing and remains a catalyst for re-imagining options for plastic parts. Advancements in this technology are leading to some impressive results with direct benefits for certain OEMs, including prototyping.

6. Automation & industry 4.0

Automation is meeting the plastics industry demand for process simplification and cost savings. The advent of Industry 4.0 provides prime opportunities for further integration of robotic technologies and machine controls.

The above-mentioned trends connect with HYPPOS in many ways:

The implementation of HYPPOS can reduce resource usage, for example, energy, water, and/or feedstock.

HYPPOS enables waste reduction, recycling, renewable feedstock, and novelty.

HYPPOS can result in a reduction of 4 million kilograms of Carbon Dioxide per month per plant.

Not all plastics are created equal: some are recyclable & some are not

Plastic is everywhere and we know it when we see it, but knowing the difference between the various types of plastic needs elaboration. Furthermore, plastic is one of the most complicated materials to recycle, in part, because consumers don’t know what types can be recycled and how. Below we explain the different types of plastics and their recyclability. A product made of plastic is stamped with a resin code, a number between 1 and 7 inside a triangle made of arrows (♺). Each number corresponds to a type of plastic and indicates its recyclability.

♳: PET/PETE (polyethylene terephthalate): a wrinkle-free fibre used to make beverage bottles and containers for various food items due to its strong ability to prevent oxygen from entering and spoiling the product; it is also able to keep the CO2 of carbonated drinks from escaping. This can be recycled.

♴: HDPE (high-density polyethylene): used to make bottles, such as milk jugs, cleaning product containers, and detergent bottles. This is the most commonly recycled plastic because it doesn't break under exposure to major heat or cold.

♵: PVC (polyvinyl chloride): a soft, flexible plastic used for many household products, such as pipes and flooring. This contains toxins harmful to health and the environment and is not recycled.

♶: LDPE (low-density polyethylene): used to make plastic wrappings, such as plastic bags, and can sometimes be recycled.

♷: PP (polypropylene): a stiffer plastic and is more resistant to heat. This is widely used for hot food containers, straws, bottle caps, and can sometimes be recycled.

♸: PS (polystyrene): used to make disposable styrofoam egg cartons, disposable cups, and packaging. This is lightweight and easy to form into plastic materials. This can sometimes be recycled.

♹: Other resins: a plastic that doesn’t fit into any of the 6 categories above and often made of multiple plastic types (e.g., acrylic, nylon, polycarbonate, polylactic acid). These aren't easy to recycle, unless exposed to high temperatures.

Environmental sustainability has increased in importance for people, environment, and industries universally. A sustainable environment promotes sustainable economic development.

Circular economy (CE) is a non-linear model of production and consumption that involves reusing and recycling existing materials and products for as long as possible. CE is a deviation from the traditional, linear economic model (take ⇨ make ⇨ consume ⇨ trash). The following is a schematic of CE:

Consequently, the lifecycle of products is significantly extended. In essence, CE implies reducing waste to an absolute minimum. When a product reaches end of life, its materials are kept within the economy wherever possible. These materials can be productively used over again, thereby creating further value. CE relies on cheap, easily accessible materials, and energy.

How does HYPPOS fit into CE?

Carbon footprint reduction:

HYPPOS can reduce greenhouse gas emissions by up to 63,000,000 tons of CO2e per year, which is equivalent to 58 coal-fired plants or 50,237,860 cars driven for 1 year.*

Resource efficiencies:

HYPPOS can reduce resource usage, e.g., energy, water, and/or feedstock. Through waste reduction, plastic manufacturers can achieve savings of up to €25 million per plant, per year, due to improved efficiency in the production process, coupled with current and future compliance costs to the EU-ETS.*

HYPPOS contributes to CE by enabling the following:

HYPPOS enables waste reduction, recycling, renewable feedstock, and novelty.

(image & video credit: EU Parliament)

We have received 4 renowned awards for HYPPOS: the Seal of Excellence from the European Innovation Council 3 times and a prestigious grant from the Cyprus Research & Innovation Foundation.

Seal of Excellence: June 2018, February 2019 & June 2019:

Opportunity/0916/SME-II Grant Award:

10 facts about HYPPOS

HYPPOS is an integrated, easy-to-configure, fast-to-install, highly compatible, decision support tool for use in continuous and semi-continuous production plants. Here are 10 facts about HYPPOS you may or may not know:

HYPPOS continuously collects data in real-time from plant instruments and feeds this data into its tracking model.

HYPPOS has a material tracking algorithm that uses real-time process values to track continuous movement of liquid, powder, and granular material by segmenting and characterizing material into discrete quantities.

A configurable workflow module, in HYPPOS, reacts to process events and data relating to a process, for example, interacting with the operators for batch production from initial batch creation through quality testing and packaging. This workflow module has the capability to interact with plant operators where defined processes require data, approval, or other forms of intervention.

HYPPOS boasts a modern web-based graphical user interface, which means that it is secure, platform-independent, and can be accessed 24/7. Users, allocated with appropriate permission rights, can collaborate easily either in one location or across various sites and geographies.

Using the innovative online analytical processing capabilities of HYPPOS, visibility is provided, quality issues can be identified and tracked in real-time. This allows for corrective actions earlier in the process, leading to improved product quality and less waste.

HYPPOS comes bundled with several pre-configured, built-in reports. Many more reports can be configured as per the customer’s needs and requirements, and deployed within HYPPOS.

HYPPOS provides seamless integration with various external systems, such as Open Platform Communications engines, Enterprise Resource Planning systems, and Laboratory Information Management Systems.

HYPPOS is an all-in-one deep tech decision support toolkit, whose deployment becomes faster and less costly.

HYPPOS tracks quality issues from the start, in real-time, which allows for corrective action earlier in the process and, therefore, more first time right polymer product. This means less energy consumption and CO2 emissions, transitioning to a sustainable manufacturing processes.

HYPPOS is an integrated, easy-to-configure, highly compatible, decision support tool for use in continuous and semi-continuous production plants.

A major part of quality assurance is to keep records of raw materials, process conditions, as well as analyses during each batch production. HYPPOS can easily feed its data, in real-time, to other management reporting systems or visualisation platforms. The above-mentioned data can be combined with data from various other sources (e.g., financial data and/or sales data from an ERP).

HYPPOS comes bundled with the following pre-configured reports:

Batch Summary Reports

Detailed Batch Reports

Additives Reports

Grade Daily Reports

Quality Reports

Scrap Details Reports

Production KPIs Reports

Production Quantity Reports

Detailed Production Reports