The Race to Save the Planet

in which all of the conveyors, label dispensing, wrap, and metering wheel speeds are automatically set and synchronized without further operator intervention. This gets the operator to 90% of where the set up needs to be just by measuring the bottle. “They don’t need to understand dispense speed or any of that because we understand it, and we write in the code and algorithms to calculate the speeds,” explains BellatRx president and CEO Alan Shuhaibar. “All you need to do is measure the bottle and enter the dimensions.”

The second part of this is the physical setup. A short animation or video serves as a step-by-step guide in the HMI on how to get the BellatRx labeler up and running. The video is coupled with an LED light strip installed along the length of the machine. When setup is required to be done on a certain assembly, the section of the LED strip in front of that assembly will light up to draw the operator’s attention to that point. The mechanical adjustments include electronic feedback, which turns the LED light green when it is in the correct setpoint or red when it is not. On the HMI, the operator cannot progress to the next screen unless all setpoints for that assembly are green.

In the past, the OEM’s expectation was that the operator knew how to set up the machines. But that doesn’t exist anymore. In addition, people expect the same user-friendly interface as an iPhone. “We are trying to take that mindset and put it into the machines. You shouldn’t need a PhD to run a labeler,” Shuhaibar says.

No coding experience? No problem

In its own factories, industrial control supplier Bosch Rexroth does something similar, which it calls the ActiveAssist assistance system that guides the operator through the assembly process. It provides instructions projected on a workstation with a vision system that confirms when something is done correctly.

Separately, the maker of industrial control and motion technology has reinvented its automation approach over the last two years with its software-driven ctrlX Automation platform. Going back to the drawing board, the company erased the traditional boundaries between machine control systems, IT, and Internet of Things (IoT), creating a flexible and scalable platform based on the Linux real-time operating system, open standards, comprehensive IoT connectivity, with web-based engineering.

Using the Blockly visual programming language, the platform provides a drag-and-drop function block that builds sequentially. “So now, instead of memorizing dozens of lines of code, you just have to understand that this block means a kinematic move sequence. This makes it easy to use, and to train someone to use,” explains Brad Klippstein, product manager for smart mechatronics at Bosch Rexroth. “In under five minutes we can teach you how to use this interface and program your process.”

In addition, Bosch is helping out OEMs and customers alike by providing them with its LinSelect online tool for use in the designing and commissioning of machines. “It allows you to input the parameters of whatever you are trying to do.” If you are trying to move boxes from point a to point b, for example, just input the distance needs, weight of the box, and a few other details pertinent to the process. “Our system sizes and selects the mechanical, electrical, and software components that fit together based on your application.”

The Ewon router provides a secure remote connection to Pearson machines, allowing tech support to see the state of the PLC and more.

And if all else fails…

Of course, the easiest thing for OEMs to do to help their customers is to fully manage the machines onsite. However, the thought of allowing a third party to remotely control a machine is completely off-limits. Or is it?

Desperate times call for desperate measures. Given the current circumstances, it’s becoming acceptable to relinquish control to the experts. “We always have a plan b with the remote connection of a machine,” says Pearson’s Patrick. “We have the ability to take over the machine, so if an operator is not comfortable doing something, they can grant us access to use the HMI remotely.”

To be clear, this scenario requires specific conditions with the machine in a certain state in order for it to work, Patrick notes, emphasizing, “there is no opportunity to put someone in danger.”

But, even this one small step for remote control of machines is a big deal, and something the manufacturers could ultimately be asking for.

“It’s always a challenge with our IT team to remote into anything in the brewery,” says Anheuser-Busch’s VonderHaar. “And that’s just because of the risk. But I think the trend is there, and we have to figure out how to do that. And at the end of the day, yes, we want to do that. We need to figure out how to do that safely and try to do it in a manner that doesn’t put our operations at risk.”

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Innovation in Packaging and Processing

The Technology Excellence Awards Winners announced at PACK EXPO International

Stephanie Neil, Editor-in-Chief

The winners of the 2022 Technology Excellence Awards were announced in October at PACK EXPO International in Chicago in the categories of Food/ Beverage, General Packaging & Processing, Personal Care/ Pharma, and Sustainability. What started as months of reviewing 60 qualifi ed entries by a panel of PMMI Media Group editors and industry professionals, culminated in three days of onsite voting by show attendees who ultimately decided which companies showcased the most innovative materials and technologies at the show. “Congratulations to this year’s winners for their outstanding materials and technologies,” said Laura Thompson, vice president of trade shows at PMMI, The Association for Packaging and Processing Technologies, which owns and produces PACK EXPO. “The abundance of quality entries received this year made the selection process quite challenging. We are proud to celebrate and showcase the best of the industry, and encouraged to see that the Technology Excellence Awards are attracting the top innovations.”

Here’s a look at this year’s four winners:

Food and beverage

Berry Global, Inc.—Proxima Tethered Closure

The Proxima tethered closure provides a solution to enhance the recyclability of the closure while still offering consumers a convenient and comfortable drinking experience for cold fi ll and aseptic applications, including still water and functional drink.

The design of the closure features a special feature on the tamper-evident band that means once the band has been broken, the closure remains attached. When the bottle is opened for drinking or pouring, the closure is placed adjacent to the neck at a wide angle, thus ensuring that consumer convenience in not compromised in any way but enabling easy reclosing of the bottle.

This solution meets two important sustainability benefi ts. Because the closure remains with the bottle and is not thrown away at any time, recycling rates for the closures can be greatly increased. Equally important, keeping the closure on the bottle avoids the danger of littering and unnecessary plastic waste when closures are carelessly or thoughtlessly discarded.

General packaging and processing

IMA North America Inc.—IMA Ilapak Vegatronic 6400

Hygiene, accessibility, and effi ciency are the trademarks of the IMA Ilapak Vegatronic 6400 continuous motion vertical bagging machine developed to meet the specifi c needs of highly demanding industries in terms of sanitary design, accessibility, fast changeover, and OEE. Full open-frame design and IP66 through IP69K rated electrical components are some of the features of this cutting-edge machine.

Fully AISI 304 film reel carriage, rollers and bearings, sloped cabinet tops and splicing table, inclined forming tube support, EHEDG compliant electric panel are the main features that limit the areas where product can accumulate and harbor bacteria, making this bagger ideal for harsh environments where hygiene and sanitation are primary requirements.

Accessibility is granted by fully openable front and side doors to make sure every single component of the machine can be reached by operators or maintenance people as fast as possible with the lowest downtime.

Efficiency on the Vegatronic 6400 has been enhanced in several ways. Improved usability of the HMI by introducing auto-adaptive and multiclient features to make the setup easy and fast. The splicing table is vacuum assisted, making it very quick to operate. The forming tube is mounted on a swivel arm for easy changeover. And, the film reel shaft is pneumatically activated in a variety of executions to meet the customer requirements, i.e single cantilevered or drop-in, dual reel holder, or automatic splicing system to further enhance efficiency.

Personal care/ pharmaceuticals

Eurotrol—CueSee Mix/Dual Chambered Device for storage of liquids/ powdered/lyophilized components

CueSee Mix is a unique, patented packaging form that is revolutionizing the In Vitro Diagnostics (IVD), pharmaceutical, and cosmetic markets. The innovative, dual chambered device keeps various fractions separated, preventing reactions between components of the desired matrix. A simple twisting motion allows the previous separated components to combine. After mixing via a “static stirrer” the product is ready to use by either the integrated dropper bottle or aspirating into a syringe. CueSee Mix eliminations the need for manual combination or dilution of product components while providing added ease of use and increased safety.

Sustainability

ability to run two different paper-based multipack styles on the same machine, the ClipCombo solution uniquely allows rapid changeovers and delivers high speeds no matter what is running.

The ClipCombo range offers machinery solutions for multiple combinations, including: • KeelClip and EnviroClip paper-based clips for can multipacks • GripClip and EnviroClip paper-based clips for can multipacks • Cap-It and EnviroClip paper-based clips for PET bottle multipacks

Graphic Packaging International—ClipCombo

The ClipCombo machinery solution is the latest machinery innovation from Graphic Packaging. Delivering the To learn more about the 2022 winners and finalists go to: oemgo.to/technologyawards2022