MOVING IDEAS
Secondary packaging Wraparound Case Packing: techniques, solutions, comparisons and the benefits of the technology that has revolutionised the packaging industry and distribution chain.
Text by Vincent Bandini, Manuel Bolzoni, Giuseppe Buttazzi, Gabriele Folli
OCME Competence Library
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LYNX
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Secondary Packaging Wraparound Case Packing: techniques, solutions, comparisons and the benefits of the technology that has revolutionised the packaging industry and distribution chain.
Contents Secondary packaging: why it is necessary to protect the product
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Technology compared: wraparound case or American case?
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OCME wraparound packing
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Altair, the synthesis of over 40 years experience in wraparound technology
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Container infeed, pack selection, blank magazine, dispensing system
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Partition insertion, format changes
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Wraparound packing and the Altair: the perfect combination to cut your costs
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Altair: a new lever for marketing
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Altair and respect for the environment
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OCME Competence Library
www.ocme.it
5
Secondary packaging Why it is necessary to protect the product “Concern for man and his fate must always form the chief interest of all technical endeavours. Never forget this in the midst of your diagrams and equations.� Albert Einstein (1879-1955)
econdary packaging was originally developed to protect the product, or to make it easier to hold several items together. In fact, these features remain important for the packaging industry today, but in addition we now have to consider other factors such as marketing, logistics and, in some cases, the technological process. Nowadays in particular, secondary packaging is often required to carry graphical images and therefore serves as an important medium for brand identity during the distribution chain. 1 Quite often the secondary packaging case itself becomes the sales unit and it must therefore be sufficiently manageable, robust and attractive to the consumer, whilst being able to carry all the relevant product information. Some products need to be protected from light and heat and both of these requirements can be fulfilled by having a secondary protective covering. At present, most products in the beverage, wine & spirits, petrochemical, edible oils, food and pet food sectors are contained within one of three types of secondary packaging: cardboard cases, shrink-film and rigid plastic crates. We will concentrate on the first of these by illustrating the main concepts and by explaining the technology associated with wraparound case packing equipment. Case packing offers important advantages; for example, it protects the products inside the case from mechanical stress, abrasions and knocks. A cardboard case offers far greater security than a shrinkwrapped pack and, compared to a rigid crate, it weighs less and takes up less space. Furthermore, case-packed products are usually more stable and are therefore not subjected to the movement associated with products that are packed within the rigid structure of a crate. The thickness of the cardboard acts as a shock absorber for the product within and therefore minimizes impacts during movement of the case. A cardboard case can be printed, just like shrink-film, and offers an ample flat area on which to carry a decorative graphical image. This feature is particularly useful from a marketing point of view, as it creates a means of communication with the consumer and distributor. Unlike crate-packed goods, products that are packed into cardboard cases are less subject to external factors such as light and dust – these can be important issues in many market sectors. Apart from this, a cardboard case is easier to handle than a shrinkwrapped pack, as it is more stable and less susceptible to damage; a cardboard case is lighter than a crate, therefore it requires less motorised force to move it. The use of a cardboard case also avoids the logistical problems associated with returning empty crates.
S
Figure 1 Detail of case squaring system
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OCME Secondary packaging
Technology compared: wraparound case or American case?
c
ase packing technology is divided into two main systems: Wraparound case packing and the top-opening American case. The difference between the two concepts is very simple: the American case is erected prior to being filled with the product, whereas the wraparound system forms and seals the case automatically around the product. The two types of case may appear similar and the material used is often the same, but there are significant differences which should be carefully considered before deciding on one system or the other. The forming of an American case requires the use of three machines: the first erects the box, the second inserts the product into the box and the third closes and seals it. The wraparound system on the other hand uses only one machine, the wraparound packer, which begins with a flat cardboard blank that is wrapped around the products and sealed with jets of glue. Thanks to this system a single machine can reach a production speed of 80 cases per minute, well beyond the capabilities of American case packing technology, while at the same time taking up less space and offering lower complexity.
One important observation should be made immediately: wraparound technology offers more production capacity in a smaller space, but not just this – one machine against three means lower installation and maintenance costs. It should also be noted that the deployment of personnel on each system is very different. American case packing machines require a full-time operator, while wraparound packers only need an operator to feed the consumable materials - an activity which can be automated to a large extent. A single operator can therefore cover two wraparound machines on the same line without assistance from other personnel. Another advantage of the wraparound system is that the cardboard case is designed to fit precisely the set of containers, making it extremely compact. The American case has to be slightly bigger in size than the containers which are inserted into it. This means that it is often essential to use partitions between the containers to protect the product and avoid damaging the labels. Finally, it is important to point out that on the wraparound system, the weight of the glass (in containers such as bottles) can sometimes be reduced because of the greater protection and the compact packing it offers.
Figure 2 Case coming out from the squaring system: Note the 4 black polyzene lateral guides, which are adjustable in both height and width and are spring-loaded in order to guarantee positive pressure on the ends of the case during the gluing phase.
Figure 3 Detail of the draw guides used on the blank dispenser: maximum precision and reliability are guaranteed by the self-cleaning belt system
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The American Case
Wraparound Case
The American Case involves the use of three machines which serve to erect the box, insert the bottles or other containers into it, and finally to close up the case. The case is normally fairly large in size in comparison to its contents, and this can cause greater internal instability. Partitions are often used to reduce the risks of friction and breakage between the containers.
The pack obtained with the wrap-around case packer is, as its name suggests, a piece of cardboard wrapped around a group of containers such as bottles, cans, multi-packs, etc. The single machine deals with the entire process; from the selection of the containers right up to the closing of the box. The resulting pack is very compact thanks to the reduced tolerances achieved through compression.
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8
OCME Wraparound Case Packing
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ot all manufacturers of wraparound case packers use the same working logic. Ocme in particular has developed its own solution for gluing the pack with the long side of the case leading. What does this mean? A cardboard case is a rectangular block, the sides of which (seen from above) are not equal. A case can run through the case packing machine with either the long or the short side leading. OCME’s solution guarantees that the side flaps are closed as securely as possible with a jet of glue emitted from suitably positioned spray guns. Apart from the facility to vary the case dimensions, the lateral guides on the side compression section are spring loaded, which means that they work in the optimum position to assure a high quality result. The compression ensures that the glue is spread
OCME wrap-around system
in a uniform fashion over a wide area, offering maximum resistance once the case is sealed. The Ocme solution is more efficient since it also requires a smaller quantity of glue which, as we will see later on, has important implications for safeguarding the environment and also for company overheads. The solution of forming the case with the long side leading, combined with OCME’S guide system, guarantees that the finished case is as compact as possible. The most striking feature however, of this solution, is the quality of the final pack. With “long side leading” technology, case folding is achieved using motorised drives and not just fixed guides. In this way the cardboard is forced against the product, guaranteeing a much more compact pack. The “long side leading” technique ensures that the containers are pushed against one another and this avoids any looseness in the resulting case.
Seen from the glue nozzles
Useful area of glue application
Running the case with the long side leading enables the glue nozzles to work as efficiently as possible to achieve a precise and efficient bead of glue.
Time margin available to achieve optimum jet
Duration of packaging cycle
9
Wrap-around system used by competitors
Seen from the glue nozzles
Useful area of glue application
The packaging solution with short side leading forces the glue jets to work with the minimum margin of tolerance, also the position of the jets is penalised because of their elevated angle in respect to the case. The result is a glue deposit which is often not suitable for guaranteeing an adequate seal for the case.
Time margin available to achieve optimum jet
Duration of packaging cycle
10
OCME Secondary packaging
Altair, the synthesis of over 40 years’ experience in wrap-around technology
o
CME’s first wraparound case packer model came out in 1964 and was installed years ahead of rival solutions. Since then, Ocme has followed a programme of continual development and improvement which has led to the Altair range we have today. The Altair is synonymous with wrap-around technology and Ocme machines are known to be among the most reliable, efficient and productive in the world. This is a source of pride for Ocme and also acts as a motivation to maintain an exceptional level of quality throughout the life of the equipment. Altair in detail One of the leading principles applied throughout the Altair project has been the mechanical simplification of the machine. This
objective is achieved through the use of brushless servo motors on the main assemblies. The Altair has been designed to operate on a continuous 3-shift basis in high pressure production environments. Therefore, we use oversized components, particularly on the chain transmissions. Selflubricating chains eliminate the risk of cases being contaminated by grease or oil and also reduces the cleaning required to remove dirt caused by the mixture of oil and cardboard dust. The Altair can pack numerous types of container (plastic, glass, round, square, oval, triangular etc.) Our designers pay particular attention to the types of container being handled in order to avoid breakages or damage to the labels and to maintain the highest quality standards of the product.
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Figure 4 The transmission chains are oversized and self-lubricating, to guarantee long-term reliability.
Technologies compared American case
Wrap-around case packer short side leading
OCME wrap-around case packer long side leading
= + + -
+ + + = = + = + + +
+ + + + + + + + + +
Space occupied on the floor Capability to handle trays Shrinkwrapping on the same machine Compactness of case Necessity for partitions Glue consumption Glue effectiveness Time required for format changes Cost of format changes Re-use of cases Reduction in weight of glass
+
Positive
=
Neutral
-
Negative
This table provides an outline of the advantages and disadvantages of the different case packing technologies. We have considered the main features in relation to costs (both in terms of raw materials and labour), versatility and features relevant to the primary containers.
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OCME Secondary packaging
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Figure 5 Robotic gripper picks the cardboard blanks directly from the pallet. This option offers greater autonomy in feeding materials to the wraparound packer.
Figure 6 The loading conveyor delivers stacks of blanks from the robot and feeds them periodically to the magazine.
Figure 7 The design of the infeed to the packer is based on the particular shape and features of containers so as to avoid the risk of damage.
Figure 8 The electronic selection system guarantees optimum selection of each group of containers.
Figure 9 For high speed (70 to 100 ppm) a double selection system is provided (Electronically adjustable fingers & counterfingers).
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Container Infeed Fundamental to the success of the machine is the design of the infeed - to avoid blockages in the flow of containers and to ensure smooth size change-overs without the need to carry out further adjustments. In this regard, the Altair benefits from certain unique features which enhance its operation: profiled guides that are specially designed for each container shape, flow regulation systems which prevent jerky stops and starts, and a channelising bridge which is only activated when a blockage is apparent. Product Selection The aim is to select the necessary number of containers, without them falling over or being damaged, whilst minimising the amount of time required for size change-overs. Two servo motors, controlled by the PLC, are used to separate the bottles (or containers) on the Altair system. Changing the size, or format, simply involves the substitution of the 4 finger selecting bars if the diameter of the container changes. For speed between 70 and 100 ppm a double electronic system is provided (fingers & counterfingers). With this double device the speed vary from the infeed to the wrapping in 3 steps: • Infeed • Electronic fingers selection (2 brushless motors) • 2nd electronic counter-fingers selection (2 brushless) This system allow: • Smooth passage between line speed and wraparound packer speed allowing a wider pitch of the machine • With a wider pitch the machine can work at a lower relative speed with minimum stress. • Maximum stability of the container even at very high speed. Figure 10 The standard blank magazine, ergonomically positioned at operator level, rather than being positioned under the machine.
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Blank Magazine This is the only area of the machine which requires the presence of an operator. The magazine therefore needs to be easily accessible and have a high capacity. The standard capacity on the Altair range is approximately 600 blanks; the magazine is positioned at a comfortable height for the operator which does not put him at risk of a working injury or strain (the operator is typically required to lift about 5,000 Kg of banks in 8 hours). There is the option to completely avoid manual handling of the blanks by fitting a robotised system, designed to lift the blanks directly from the pallet that arrives from the board supplier. This increases the capacity of the magazine to about 1,000 blanks. Blank Dispenser The dispenser is the assembly dedicated to feeding the blanks and the aim here is to carry out this function as simply and reliably as possible, avoiding wherever possible complications in the system. The Altair dispenser has continuous control over the position of the blanks, thanks to a photocell which allows perfect synchronization with the introduction system. The dispenser is fitted with high friction draw belts which ensure maximum long-term reliability, even with high production volumes, avoiding the problems caused by the now obsolete suction cup systems. The belts are cleaned periodically by an automatic brush system, which rids them of any dust and ink left by the printing on the blanks.
Figure 11 The helical brush in the introduction area guides the blank and maintains it in position.
Figure 12 Wraparound packing allows precise fitting of the group of containers inside the carton.
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11
12
13
14
OCME Secondary packaging
13 Pusher
Guides
Coupling of containers – blanks The aim is to guarantee the coupling of the containers to the blank without knocking the containers in any way and avoiding breakages or damage; furthermore the set of containers needs to be simultaneously held together on all four sides without any of the containers falling or the collation coming apart. On the Altair machine, the position of the blank and the containers is controlled electronically, so as to ensure that they run at exactly the same pace. The parameters for the different configurations are automatically set by the programme and the wrapping mechanism is designed to support the primary containers on all four sides. Closing and sealing The objective here is to achieve the highest quality standard for the finished case, while making the case as compact as possible and rationalising the use of glue. The Altair uses mechanical devices to close the side and upper flaps. They enable active pressure to be exerted on the flaps themselves, thus making the closing operation a lot more reliable. The glue nozzles are mounted in a perpendicular
position in respect to the jet’s point of impact; this compares to other types of system which have to emit a jet at a very tight angle in a reduced time and space from more than one position. Such designs are detrimental to jet quality and the subsequent compression / sealing of the flaps; the glue deposited in this way is often distributed in uneven concentrated spots or stretched in a single filament. In both these cases the glue is not diffused correctly and therefore the adhesive surface is vastly inferior compared with the OCME system. The lateral compression guides are divided into sections and manufactured in a material with a low coefficient of friction; they are spring-mounted in order to achieve a continuous and homogeneous positive pressure on the flaps when the case passes through the compression section. As the height of the case varies, the compression guides adapt to work in the best possible position. To offer extra efficiency and autonomy, an extra reservoir for the hot-melt glue is available. When a minimum level is reached in the main tank, it is automatically topped up from the reservoir.
Figure 13 The group of bottles is contained between the lateral guides, the pusher and the blank, so that it does not fall over and the collation is maintained.
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Figure 14 Coupling between the blank and the containers takes place at the same speed in order to avoid breakages or damage.
Figure 15 The side and upper flaps are closed by mechanical devices and not just fixed guides, thereby ensuring a more effective seal to the pack.
Figure 16 The optional glue reservoir gives greater autonomy to the operator.
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16
15
16
OCME Secondary packaging
17
Figures 17 and 18 Each part that needs to be changed or adjusted is colour-coded and has its own reference number for ease of changing formats.
17 18
Partitions In some circumstances it is necessary to provide further protection to the product inside the case. Cardboard partitions are used for this and they are inserted during the machine operating cycle. The Altair is able to handle both kinds of protection technology available: traditional partitions and pre-formed partitions. The first type, often manufactured in corrugated cardboard, offer increased resistance against knocks and are therefore recommended for products which have to be transported over long distances, such as, for example, goods destined for export. The traditional partitions are fed from various insertion magazines that are appropriately placed along the case packaging line. The pre-formed partitions use low-cost, preassembled, solid pressed cardboard, which protect the containers and also their labels from abrasion. The pre-formed insertion system consists of a side loader, readily accessible for re-fill, and a 3-axis robot which picks the partition from the magazine, opens it and then places it between the containers as they run down the line.
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Format Change Format change has been the subject of intense rationalisation analysis in order to achieve the best overall result. For this reason we turned to an electronic solution in order to simplify the machine functions, to reduce the number of components and to eliminate potential problems. We opted for a step-bystep guided procedure, which can be followed by a single person without any special training (including temporary and seasonal workers) with parts which can be easily identified via colour/number coding. Once the automatic change has been put into effect, the Altair can go straight into full production without the need for fine-tuning, because it is impossible to make errors of adjustment or misunderstand the instructions.
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As an option, the Altair can be fitted with a PC which guides the operator through the various operations using a personalised procedure. This makes the format change procedure much simpler to follow (even for the least expert of operators), as the operations are carried out in the right sequence.
Figure 19 Twin-belt divider from 1 to more lanes.
Figure 20 Blank magazine for traditional insertion partitions.
Figure 21 Robotic feeder for pre-formed partitions
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Wraparound case packing and Altair, the perfect combination to cut your costs A truly efficient and rational system can only be achieved through a deep understanding of the packaging sector and the technology applied to it.
a
s we have already described in preceding chapters, the choice of wraparound case packing has the immediate advantage of lower production costs, in addition to the particular benefits which are exclusively on offer with the OCME Altair system. Unlike alternative packaging solutions, only one operator is required to manage the Altair wraparound case packer; the fact that the machine operates totally unaided means that the operator is only required to load the blank magazine and other consumable materials (such as glue). Apart from the reduction in labour costs, there is also the benefit of a reduction in the cost of raw materials, in particular glue and glass. Indeed, perhaps it is the glue which offers the greatest cost saving on the Altair: not only is a smaller quantity required because of the revolutionary technique of forming the cases with the long side leading, but also the quality of sealing the case is higher in comparison to other solutions. The possibility of using lighter glass for containers should also be taken into account when comparing the American case packing system, as the greater compactness of the products lessens the risk of breakages. The OCME range of Altair wraparound case packers is noted for its high quality standard. This has been achieved through excellence in design, our insight into the needs of the industry and the choice of high quality components used to build the machines. This last item offers one of the greatest cost savings. Poor machine performance costs far more than high quality components and has a negative bearing on production programmes. Customers using the OCME Altair can stay focused on their business while knowing that they have the most efficient and reliable machines available; machines which satisfy the demands placed on them by today’s modern distribution channels. A further economic benefit is seen in the re-designing of assemblies and components to offer commonality of parts across the whole OCME range, which enhances stock availability. The consequences of this are shorter delivery times and more efficient maintenance. Speed cases/min
Dimensions mm (L x H)
30
8280 x 2200
30 •
11042 x 2200
ALTAIR N 40 ALTAIR N 50 ALTAIR N 60
40 50 60
11.665 x 2.200
ALTAIR N 70 ALTAIR N 80
70 80
14.655 x 2.250
ALTAIR A 40 P1 ALTAIR A 50 P1 ALTAIR A 60 P1
40 50 (40 •) 60 (40 •)
13150 x 2250
ALTAIR A 50 P2 ALTAIR A 60 P2
50 • 60 •
18.200 x 3.165
ALTAIR A 40 ALTAIR A 50 ALTAIR A 60
40 • 50 • 60 •
17850 x 2250
ALTAIR A 70 P2
70 •
20.200 x 3.165
Altair range
ALTAIR X 30
ALTAIR X 30 P1
• with pre-formed partitions
• with traditional partitions
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OCME Secondary packaging
Altair, a new lever for marketing
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ven though Altair wraparound case packers are primarily considered as an important tool for Production and Logistics departments, they can also be seen as an excellent aid for marketing. The varied aspects of the Altair machine combine to make an important resource to meet the growing demands of modern distribution. Thanks to its flexibility, the Altair system can create varied and innovative packaging. An ample surface area is available for graphics, enabling the user to project its image on the case to the final consumer, whilst at the same time making sure that the goods arrive intact to the distributor. The Altair also has the ability to produce cases which are easy to open, it can produce trays and other kinds of special packaging to greatly extend its original role of simply providing secondary packaging to that of providing a
display, which is simple but at the same time functional and economical. The wide choice of board available varies from micro-flute corrugated cardboard to highresistance 5 mm card. Interesting applications can be achieved by combining different types of card, such as a board consisting of normal corrugated cardboard to which off-set printing is applied; in this case a surprising level of graphic quality can be achieved, thanks to high definition images of continuous tone. Many manufacturers see wrap-around cases as a useful way of enhancing their brand; there are benefits to the product at the point of sale, the pack can be made easier to manage by perforated handles and it gives the distributor the possibility of displaying the secondary packaging directly, so drastically reducing the manual activity involved in restacking shelves.
Some examples of packaging created using Altair
Internal flap
Top opening
Tear-strip opening
Pack with carry handle
Open-top case
External flap
Assisted opening
Tray
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Altair and respect for the environment
i
ndustry is being asked more and more to respect the environment by exercising a more rational use of raw materials. Particular attention is paid to packaging firms by the public because of disposable and recyclable packaging. Choosing OCME means joining in our concerns for respect and protection of the environment. Back in 2004, we started WorldCare, our corporate environmental policy which centres on pollution and recycling. This policy is a driving force for our designers as they develop new solutions which reduce the ecological impact of industrial production. In the case of the Altair it is clear that
rationalising the use of raw materials coincides with substantial cost savings. As already evident, the considerable reduction in the quantity of glue necessary for sealing the packs (now only 4.5 g of glue per case) represents reduced reliance on a petroleum derivative, and also, albeit to a lesser extent, a saving in the energy required to keep the glue heated to a certain temperature. Thanks to the new blank dispensing system, it is quite possible to use recycled cardboard blanks, without encountering the previous problems of surface dirt and abrasions which used to cause stoppages and premature wear on some components.
Corporate environmental respect programme
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We believe that it is our duty, as a supplier of packaging technology, not just to install a machine to answer an immediate problem, but also to offer a vision of the future of packaging and to come up with solutions which anticipate future developments. This has been our mission since 1954. Since then, OCME has established itself as a world leader, and, particularly in secondary packaging and wrap-around case packers, has achieved some of the milestones in the history of packaging. We have presented our experience and our vision of secondary packaging in this document, placing the Altair range and wrap-around case packers in context. Discussion of OCME case packers is not the same as talking about case packers in general, since it is an elite system of highly efficient machines with high productivity, a system developed to create the backbone of our customers’ production department. OCME has also worked on a crucial aspect which is ultimately the most important one for our customers: Total Cost of Ownership (T.C.O.) In this publication we trust that we have demonstrated to you how one of the best packaging systems in the world can also be highly favourable from an economic point of view.
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OCME and secondary packaging
CL-WRA-EN Rev. 1.1-0907
MOVING IDEAS