PAC K AG I N G AU T O M AT I O N
Effectively optimise packaging lines to increase productivity Technological advances such as the Internet of Things, self-learning software and artificial intelligence are fuelling the development of nextgeneration packaging equipment. By Matthew Walters. WORKFORCE VS TECHNOLOGY
monitors products in the seal and jaw area
Most packaging facilities employ a human
and immediately alerts the operator if the
workforce alongside automated systems to ensure processes run smoothly, issues are dealt with promptly and maintenance and Tna’s Robag 8
repair tasks are carried out efficiently to keep production downtime to a minimum. A good coordination of human labour and technology is crucial to ensure operational viability and profitability. Staff might be occupied with repetitive tasks that could be more accurately performed by a machine. An effective HMI can detect faults much quicker than the human eye and allow operators to react quickly to issues. This not only reduces the margin for human error and improves
W
productivity, but also frees up time for ith the ability to streamline all components of the packaging line, the latest technologies
allow operators to control a complete system from a single, intuitive user interface (UI) to promote greater productivity, reliability and serviceability. As packaging lines become more automated, effective control measures must be implemented to identify and address inefficiencies, maximise overall equipment effectiveness (OEE) and uphold
personnel to focus on more challenging
score of 100% means that only high-quality products without defects are bagged as fast as possible, with zero downtime. One of the most promising ways to achieve high OEE is to implement electrical controls integration and reporting technology, such as supervisory control and data acquisition (SCADA) systems. These solutions provide full visibility of the entire packaging line and deliver comprehensive diagnostics (for each piece of equipment) to a single platform, where the information is logged on a central database to create detailed reports. Easily accessible from a clear and concise human machine interface (HMI), the analysis of these documents can help operators expose inefficiencies, and develop a correction plan.
to real-time image processing, the latest date coder technology can automatically detect print defects. A mismatch between the intended and the captured image will be evaluated on the spot and trigger an alert, so issues can be addressed promptly to reduce waste and downtime.
TAKING SUSTAINABILITY TO THE NEXT LEVEL With increasing automation comes a rise in
operators significantly lower a packaging
As automation becomes a central part of
line’s energy usage and carbon footprint. By
many packaging lines, products are bagged at unprecedented speeds, increasing the chances of damage or breakage. Often caused by inaccurate control equipment or badly tuned processes, material waste is a significant problem for many plant managers and can affect the entire packaging cycle.
production breaks and excessive wastage.
and product quality of a packaging line. A
standards and minimising waste. Thanks
REDUCING WASTE EFFECTIVELY
ACHIEVING 360° VISIBILITY
(speed and throughput), machine uptime
that each bag meets the highest quality
energy consumption. While this is inevitable
If unnoticed, just one fault could cause
productivity, OEE, measures the performance
This allows plant managers to remove bags quickly from the line for inspection, ensuring
projects that require human intervention.
operational profitability.
The gold standard for calculating
seal integrity is compromised.
damage to many goods, resulting in lengthy With a detailed user requirement specification (URS), control system providers can help identify the required key performance indicators (KPIs) that an individual manufacturing process requires. Once analysed, the URS is then translated into a functional design specification (FDS) that can be used to tighten the process. The result is a much smoother and more reliable product flow that minimises waste and production downtime, contributing to greater OEE.
to some extent, leading technologies can help
implementing power saving software, the partial and phased shut down, and power-up components of equipment can be automated, which optimises the use of resources — from power to compressed air consumption. This helps plant managers improve economic efficiency, while lowering their operations’ environmental impact.
PARTNERING FOR SUCCESS To maximise productivity and minimise waste and energy usage, while also upholding the profitability of operations, it is fast becoming essential to implement controls across the packaging cycle. Joining forces with the right turnkey partner can help operators select and install the best-suited system, as well as effectively maintain equipment to support continued production efficiency. The result: consistently high productivity rates, while continuing to work sustainably. •
Innovative equipment elements such as stripper tube closures, product-in-sealdetection (PISD) software and intelligent air-free date coders with built-in verification technology can also be implemented to keep waste to an absolute minimum. The stripper
ABOUT THE AUTHOR MATTHEW WALTERS is tna general manager, South Africa.
tube closures guarantee a fast and accurate product transfer with minimum waste by ensuring no products are lost by falling through the seal area, while PISD software
tna solutions – www.tnasolutions.com
May 2020 | Food Review
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