Streamlining automation in the packaging industry
Here Stephen Hayes, managing director at automation and control specialist, Beckhoff, explores the benefits of using an integrated automation system to manage critical elements.
www.beckhoff.com
Integrated automation systems are redefining the art of precision in packaging.
In the fast-paced world of packaging, precision and speed are not just desirable attributes – they're essential. Managing the complexities of packaging operations while maintaining top-notch performance can be a daunting challenge. However, a comprehensive automation system can transform the way packaging processes are handled.
Automation solutions for packaging are already being integrated into a range of industries, including cosmetics, pharmaceuticals, medical technology and food and beverage. But which critical elements can benefit from automation?
Energy supply and fuse protection
Efficient energy supply and fuse protection are the backbone of any manufacturing process, and packaging is no different. These systems ensure that the machinery runs consistently, avoiding sudden shutdowns and production disruptions. When energy supply is stable and well-managed, the packaging process can proceed smoothly, meeting production targets and maintaining product quality.
Moreover, effective fuse protection is critical for ensuring the safety and reliability of the entire system. In the event of electrical faults, fuse protection mechanisms prevent electrical hazards and costly downtime, safeguarding both the equipment and staff.
Power distribution and voltage management
Proper management of power distribution and generation of auxiliary voltages helps reduce the complexity packaging line design. Proper voltage management ensures that each component receives the right amount of power, improving performance and reducing energy waste.
Additionally, flexibility in power distribution allows for dynamic adjustments during various production phases. This optimises energy usage, extends the lifespan of electrical components and lowers maintenance costs. A well-designed system will automatically allocate more power to components that require it, reducing wear and tear and ensuring that systems continue to run efficiently.
Precision timing and control: sequence control:
In the packaging industry, timing is vital. Beckhoff's integrated automation systems offer state-of-the-art sequence control capabilities, ensuring the synchronisation of tasks. Beckhoff’s MX-System offers a completely control cabinet-free automation solution for this. It can also be coupled with the XPlanar, which improves packaging operations with flying motion for product transportation. With XPlanar, packaging machines can be designed in entirely new ways. Filling, sealing, labelling, or sorting - each step is carried out with precision and accuracy, resulting in higher-quality products and reduced waste.
The ability to easily reprogram and modify processes is crucial in an industry where product types and packaging requirements change frequently. This flexibility minimises downtime and allows for quick adaptation to new products or packaging designs, ultimately maintaining production lines that are agile and cost-effective.
Enhancing the heart of packaging machines: motor and actuator control:
The core of any packaging machine lies in its motors and actuators. To ensure smooth and efficient operation, precise control is essential. Integrated automation systems offer advanced motor and actuator control, enabling on-the-fly adjustments to speed and torque. This reduces wear and tear, extending the lifespan of crucial components.
Real-time condition monitoring through integrated diagnostics is another invaluable feature. Predictive maintenance can address potential issues before they lead to costly breakdowns, significantly reducing unplanned downtime and enhancing overall equipment efficiency.
Seamless interaction with field devices:
Effective communication and interaction with field devices are essential for optimal packaging operations. Systems with standardised connection levels enable seamless integration with various sensors, cameras and other field devices. This ensures accurate data capture, leading to improved product quality and more efficient troubleshooting.
The open architecture of modern automation systems allows for easy integration with various communication protocols, making them compatible with a wide range of field devices. This versatility ensures that packaging lines can adapt to the evolving needs of the industry and remain competitive.
Streamlined operations, reduced downtime and improved productivity:
By integrating all these critical components into a unified system, modern automation systems simplify the management of complexity in packaging operations. The result is a well-orchestrated packaging line with minimal downtime and exceptional productivity. The ability to gather and analyse real-time data empowers packaging companies to make informed decisions, optimise processes and identify areas for improvement, ultimately enhancing overall productivity. Beckhoff's PC-based control system, TwinCAT, is a cornerstone in this transformation, capable of automating individual packaging machines or orchestrating the entire process chain of complete packaging lines under a singular software platform, ensuring streamlined control and efficiency throughout.
The packaging industry's path to streamlined automation is marked by the adoption of comprehensive and integrated solutions like those offered by Beckhoff. These systems not only simplify complexity but also optimise performance, reduce downtime and significantly improve overall productivity. With precision, speed and reliability at the forefront, packaging companies can meet the ever-increasing demands of their customers while staying competitive in a dynamic market.
www.beckhoff.com
