For the pharmaceuticals and healthcare feature in this issue, we look at the strict requirements of the pharma sector but also at medical devices and broader health
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This September’s PPMA Show lived up to expectations with the usual packed aisles, many new equipment launches and fresh features showcasing and making them more accessible
NEW MACHINERY
Combined inspection systems joining Mettler Toledo’s range bring together checkweighers from its C-Series and x-ray or metal detection, keeping cost and space contained, it says Find out more on page 17
INSTALLATIONS
Colombia’s largest soft drinks filler is said to have the fastest hot-fill line of its kind in the world, gaining 54% in capacity
Check out the new branding for Automate UK on the website and learn more about the goals of the renamed association www.automate-uk.com
Standby
November/December 2024
Contents
7 NEWS
Along with all our 2024 award winners from the PPMA Show
17 NEW MACHINERY
20 INSTALLATIONS
25 SPECIAL FEATURE PPMA SHOW REVIEW
More from the events and the exhibits around the September show, including new products
38 SPECIAL FEATURE PHARMACEUTICALS & HEALTHCARE
This regular feature examines automation in processing and packaging areas of the factory 38
REGULAR FEATURES
10 REGULATIONS
Ingress protection (IP) tests for both water and dust can be an essential part of machine design and offer important reassurance to customers. But specifying an IP-rated machine may in the end mean little if the installation of the equipment or any subsequent adaptations damage the integrity of the enclosure. When it comes to water ingress, another factor can be the proximity of spraying
21
48 WHO WHAT WHERE
Fresh appointments at Ulma, GEA and Macsa id UK, while a director returns to Holmach, Ishida Europe replaces one of its key directors, Eriez brings in a new vice president and there are management changes for Phoenix Contact in the UK and in Germany.
49 MACHINERY FINDER
Members’ machinery and services
EDITOR: Paul Gander paul.gander@automate-uk.com
PUBLISHING MANAGER: Bill Lake bill.lake@automate-uk.com
HEAD OF PUBLISHING: David Chadd david.chadd@automate-uk.com
APPLICATIONS FOR FREE COPIES of Machinery Update are considered from specifiers, managers and purchasers of processing and packaging machinery in the UK.
John Good Ltd, Progress House, Butlers Leap, Rugby CV21 3RQ Tel: 02476 652800
The Processing and Packaging Machinery Association assumes no responsibility for the statements or opinions, whether attributed or otherwise, in Machinery Update.
This publication is copyright under the Berne convention and the International copyright convention. Apart from any fair dealing for the purposes of research or private study, as permitted under the Copyright, Designs and Patents Act 1988, no part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means in any form without prior written permission of the publishers.
Excellent appearance On-pack promotion with printed film
Cost reduction
Closed packaging
No heat radiation Efficiency
Ease of operation
Flexibility
Low maintenance
Easy opening with tear tape
Biodegradable film & paper
Publishers: PPMA Ltd trading as THE BENEFITS OF OVERWRAPPING:
Automate UK matters
Backing BEST has benefits for all of us
Little
One of the key ways in which Automate UK aims to improve the life of its members – and, of course, their customers – is by hosting an event like September’s fantastic PPMA Show, which this year continued to build on its solid success story. As ever, it managed to pack an awful lot of technology and innovation into a manageable space, and was very well-attended.
However, there are other ways in which we can leverage our privileged industry position to the benefit of the processing and packaging machinery supply chain.
Our work with Automate BEST is one of the prime examples of this. And members tell us they appreciate how supporting education around STEM subjects in general and engineering in particular represents an investment in the future of their own businesses – and of the sector as a whole.
Newer developments include the setting up of the BEST Club for current and past apprentices
On one level, we organise STEM days in schools, not seeking to persuade children that their future necessarily lies in engineering but, simply put, conveying the message that engineering and technology can be the gateway to a life that is at once comfortable, stimulating and rewarding.
Secondly, for those who have chosen engineering as a career path, we want to offer support in any way we can. This could be about one-off grants to buy tools and equipment, or it may be about match funding for a Level 5 undergraduate bursary.
Awareness of – and interest in – the different routes into an engineering-based career among our members appears to be growing, certainly if the number of nominees for this year’s Automate UK Rising Star of the Year Award is anything to go by! It is truly heartening for the Automate BEST team to see such promise and enthusiasm at this critical early career stage.
Newer developments include the setting up of the BEST Club for current and past apprentices, allowing them to network and – with the generous support of their employers – take the message about apprenticeships out into the wider world.
We hope that end users, too, see the benefits of Automate BEST’s role in helping to bring new skills and vision into the industry. Customers who are keen to be more directly involved could support us by inviting BEST Club members into their factories. There is no substitute for seeing technology installed and in action. We would love to hear from you! n Richard
Mayor and management team at the Darwen facility opening
New site set to boost UK share of capacity for equipment group
Spiroflow parent group
Automated Handling Solutions & Advanced Materials Processing (AHS & AMP) has opened a new manufacturing facility in Darwen, Lancashire.
Adding the 60,000 sq ft factory to its existing Clitheroe site means that UK production capacity now accounts for 25% of AHS & AMP’s global total for Spiroflow and its three other key brands: Cablevey, Marion and Kason.
“This state-of-the-art facility provides us with the space to increase capacity, streamline operations and deliver enhanced services to our customers,” says managing director Ben Ayrton.
In 2025, further investment on the Darwen site will build up its testing capabilities.
Show creates new ways of bolstering innovation
For once, it was the number of visitors rather than the machines they had come to see making the most noise at this year’s PPMA Show, filling the aisles for the three-day event in Birmingham’s NEC.
Occupying more space than ever in Hall 5, exhibitors had no shortage of new products on offer, supported by a raft of new initiatives from show organiser Automate UK.
“It’s easy to stand still with an event like the PPMA Show, which has become something of an institution, but we introduced several new features this year: the Innovations Eleven live demonstrations, showcase and tour, as well as Inside the Exhibition,” says chief operating officer Scott McKenna. “How these and others evolve in future is a fine-tuning process, but they were well-received by
NEW TECHNOLOGY ALLIANCE COMES INTO EXISTENCE
Peak communication awaits
HMS Networks, a provider of industrial information and communication technology, has moved to acquire Germany’s Peak-System Technik, a company specialising in similar areas. According to HMS, this strengthens its position in advanced engineering communications. Pictured are: (centre, right) Staffan Dahlström of HMS and (L-R) Alexander Gach, Ines Dohmann and Uwe Wilhelm, all of Peak.
exhibitors and visitors alike.”
Footfall was impressive, too. “But while visitor numbers compared favourably with previous years, it was the quality of visitors – and the high number of enquiries and orders - which exhibitors tell us they were most pleased with,” McKenna added.
Visitors provided the PPMA TV crew with some telling views on the show, with one saying: “It’s the best way to see things, with your own
Technology company acquires expertise in emissions monitoring
ABB has agreed to acquire Födisch group, a developer of advanced measurement and analytical systems for the energy and industrial sectors.
The acquisition enhances ABB’s offering in continuous emission monitoring systems (CEMS) and bolsters its competitiveness in technology and innovation. Through the acquisition, ABB says it will widen its portfolio to meet customers’ most demanding measurement challenges across a growing range of industries.
In 2023, Födisch group reported about €50 million in revenue and had around 250 employees.
eyes, and to understand in person how things work.”
On the exhibitor side, sales and marketing director at MDS David Hale was equally impressed. “We probably see 100 of our existing customers over the three days of the show,” he told the crew. “That would take a month or a month and a half to do normally.”
• Our review of PPMA Show launches and events starts on p25.
Commitment to UN sustainability goals
Gerhard Schubert is now an official participant in the UN Global Compact Network Germany, supporting the organisation’s sustainability goals. The UN initiative brings together 10 principles in the areas of: human rights, labour, the environment and anti-corruption.
Footfall at the PPMA Show impressed, but visitor quality was even stronger
Solar panels, Schubert, Germany
Research grant funds investigation into AI-supported metal detection
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Separation technology specialist Eriez has been awarded a £100,000 grant by research and innovation agency Innovate UK, with the objective of funding R&D around artificial intelligence (AI) for nextgeneration metal detection.
The sum will support a new feasibility study designed to transform industrial metal detection in food and pharmaceutical processing, according to Christopher Dyer, lead research and development electronic engineer at Eriez Europe.
Team-working at Cardiff University
A portion of the funding is also being reserved for an eight-month research programme in collaboration with Cardiff University. As part of this initiative, Dyer will oversee a group of experts from both Eriez and the university, including several PhD researchers.
The company says this initiative builds on its established strategic partnership with Cardiff University, which has been pivotal in advancing the company’s technology portfolio. This collaboration resulted in the creation of an R&D hub at the university called Eriez at sbarc|spark.
The partnership was integral to the development of the new Eriez MetAlarm metal detector, which is specifically tailored to the aggregates sector, and was introduced earlier in 2024.
DuPont Tyvek award in healthcare goes to UK machinery design
Shawpak has won the Operational Efficiencies category in DuPont’s global Tyvek Sustainable Healthcare Packaging Awards, one of three winners in the healthcare packaging sphere.
The winners all use Tyvek material in their packaging for the sector, while demonstrating a significant focus on sustainability.
DuPont describes Shawpak’s rotary drum concept in thermoforming as a unique and “revolutionary” response to packaging needs. The machine is designed to accept multiple tool and pack sizes, and all machines are engineered to form both rigid and flexible blisters as standard. The system has been designed with no waste trim on flexible packs.
New BARA chair pledges to champion automation
BARA (the British Automation and Robot Association) has named Fanuc UK’s Oliver Selby as its new chair, as he takes over from George Thompson with support in his role from vice-chair Rosie Davies of Reeco Automation.
Peter Williamson, chief executive of Automate UK, says: “Oliver is an influential voice within the industry. His passion for all things manufacturing, automation adoption and future skills, will be a key factor in developing BARA alongside the existing committee, and with the full support of Automate UK.”
Selby, who is head of sales at Fanuc UK, assumed the new role at the beginning of October this year. As chair, he plans to drive the association’s activities forward, he says, supporting BARA’s aim to increase automation uptake while placing members’ needs firmly front and centre.
One of his key pledges is to ensure the association delivers real value to its members.
“I am excited to bring my knowledge, influence and passion for automation to a wider audience, and will be fully focused on delivering value to all facets of the BARA membership and other stakeholders – from OEM robot manufacturers and system integrators to companies in the supply chain, academic institutions and High Value Manufacturing
Catapults,” he says.
As Selby points out, despite the UK’s status as a leading manufacturing nation, it is still lagging behind the rest of the world when it comes to automation adoption. “It is essential that we highlight how automation can alleviate manufacturers’ key challenges,” he adds. W automate-uk.com/ our-associations/bara/
Italian machinery group expands further with acquisition of pharmaceutical packaging firm with turnkey capability
Omnia Technologies has built on its automation strengths across filling for spirits, wine, beverage, dairy and medical products, with the acquisition of pharmaceutical packaging machinery manufacturer Tecnomaco.
The company, based in Aprilia just south of Rome, manufactures equipment for counting, blistering, liquid-filling and capping, powder-dosing, labelling, printing and checkweighing. This range and 30 years of
experience mean it is able to supply complete packaging lines for the pharmaceuticals, nutraceuticals and cosmetics industries.
“The acquisition of
Tecnomaco significantly enhances Omnia Technologies’ portfolio of technological and automated solutions for the pharmaceutical industry, strengthening our service offering to customers globally,” says Omnia chief executive Andrea Stolfa.
“With our Life Sciences division we strive to pioneer agility in services and machinery for pharma, cosmetics and diagnostics: a brand-new concept and approach to the life sciences
space to empower our brands’ specific know-how, supporting them with our global infrastructure.”
Tecnomaco has over 80 employees and an installed base of more than 1,000 machines and production lines across 90 countries.
The Omnia investment platform brought together businesses including Della Toffola and Bertolaso in 2020. Earlier this year, it acquired Acmi, Sacmi Beverage and Sacmi Labelling.
Shawpak’s RT thermoform range
Andrea Stolfa, Omnia chief executive
Oliver Selby (left) and George Thompson at the start-of-October handover
Regulations
Ensuring the integrity of machine enclosures
Darren Hugheston-Roberts
Paul Laidler BUSINESS DIRECTOR FOR MACHINERY SAFTEY AT TÜV SÜD PRODUCT SERVICE
SENIOR MANAGER DIGITAL & INDUSTRY SOLUTIONS AT TÜV SÜD
The ingress protection rating provides a valuable indication of vulnerability to solid objects, dust and liquids, but those ratings must be maintained during installation, taking care not to create new potential leakage points and so compromise integrity
As machinery can deteriorate or malfunction when water or dust enters, it is vital to ensure that it has the correct protection for its intended use. IEC 60529 is therefore the standard that must be followed to ensure machinery is robust enough to deal with the environment within which it has been installed.
The International Electrotechnical Commission’s (IEC) ingress protection (IP) ratings grade an enclosure’s level of resistance to items entering it, defining three different types of ingress protection that an enclosure could provide against:
1. Human access to hazardous components within an enclosure.
2. Solid objects or dust.
3. Liquid ingress.
SPELLING IT ALL OUT
The IP Code consists of the letters IP followed by two digits and an optional letter. The first digit indicates the level of protection that the enclosure provides against access to hazardous parts and the ingress of solid foreign objects. It is rated on a scale from 0 to 6:
0 no protection against the penetration of solid particles, objects or dust.
1 the equipment is protected against any solid object larger than 50 mm.
2 the equipment is protected against any solid object larger than 12.5 mm.
3 the equipment is protected against any solid element larger than 2.5 mm. For example, if a machinery operator attempted to insert fine tools.
4 the equipment is protected against any solid object larger than 1 mm. For example, larger types of tools or screws.
5 the equipment is partially protected against dust.
This rating means that while dust can enter crevices within the equipment, it cannot damage it, and that contact is not possible.
6 the equipment is completely dustproof, so that dust is
1 the equipment is protected against liquid falling vertically only.
2 the equipment is protected against drops falling at an angle of 15 degrees.
3 the equipment is protected against liquid sprays in all directions, provided that they do not exceed an angle of 60 degrees.
4 the equipment is protected against splashing.
5 the equipment is protected against water projections.
6 the equipment is protected against powerful water jets, for example, if equipment is being cleaned with a high-pressure device.
Many factories are likely to spray at much closer distances than those stipulated in the IP-rated tests
unable to enter crevices so that the equipment cannot be soiled or damaged. The second digit indicates protection of the equipment inside the enclosure against harmful ingress of liquids, using a scale from 0 to 9. This covers both the amount of water and the depth of immersion, including the power of a jet. The additional letter can be appended to classify only the level of protection against access to hazardous parts by persons:
0 no protection against moisture or any liquid coming into contact with the equipment.
7 the equipment is waterproof up to a depth of 1 metre.
8 the equipment is waterproof beyond a depth of 1 metre, so water may be able to seep into the equipment, but it cannot damage it.
9 the equipment can resist high-pressure hot water from different angles. For example, IP69-rated machinery is effective against powerful hightemperature water jets used in environments that require a more stringent washdown, while IP66 is effective against powerful water jets. However, simply specifying an IP-rated machine does not
cover the fitting of any postmanufacture additions such as push buttons and indicator lights. Neither does it allow for any necessary drilling into the enclosure that is required for the addition of power cables once the machine is on site. Also, many factories are likely to spray at much closer distances than those stipulated in the IP-rated tests.
VERIFYING PROTECTION
All of this can impact the machine’s integrity, creating potential leakage points. To ensure problemfree operation in washdown areas, it is therefore important to maintain the ingress protection rating during assembly and installation. Not only does IEC 60529 define the varying levels of protection provided by enclosures, it also describes the test methods required for verifying that level of protection. IP testing reduces the risk of product failure in the field by assessing the degree of protection provided against mechanical intrusion, dust, accidental contact and water ingress into casings and enclosures. This ensures that machinery remains functional, reliable and safe for operators to use.
i For more information contact W www.tuvsud.com TÜV SÜD Product Service is Automate UK’s technical and legislative partner
Organised by
Show 2025
Automate UK Awards 2024
Multiple new categories reflect a dynamic and creative sector
With a new name, new venue at Birmingham’s Vox and greater number of more tightly-defined categories, this year’s Automate UK Awards celebrated members’ achievements across a broad range of technologies, and were presented as part of a dazzling awards night at the PPMA Show
Innovative Packaging Machinery
Multi-PurposeMachinery
Winner: Secomak
Secomak’s pioneering drying machine
DryGuide Essential, a complete redesign and collaboration with a local university, has resulted in an improved machine with lower lifecycle costs and a smaller footprint.
Innovative Packaging Machinery
Carton/CaseHandling
Winner: Endoline Automation
Endoline Automation’s Fully Automatic Top and Bottom Random Case Gluer was praised for being a unique solution devised to double the throughput of the line while using the same amount of space.
Outstanding Customer Service
Winner: Yorkshire Packaging Systems
Yorkshire Packaging Systems puts customer service at the top of its list with not only its service packages and unlimited training on its equipment but also constant, systematic monitoring to ensure standards of customer care remain very high.
More award winners than ever crammed on to the Vox stage, after an exquisite meal and ahead of entertainment from comedian Russell Kane and Boney M
Innovative Packaging Machinery
Bagging/WrappingTechnology
Winner: Votech
Votech’s VLR-B fully-automated bagging system was judged to be an innovative redesign of important areas of powder dosing and packing to improve accuracy and yield and to reduce waste.
Innovative Processing System FoodTechnology
Winner: DC Norris & Company
DC Norris & Company’s Cook, Quench, Chill, Adapt – Advanced High-Speed Cooking Technology impressed our judges with its adaptability and versatility, combining several different processes into a continuous flow.
Innovative Robotics/Automation Solution
Primary/SecondaryPackagingTechnology
Winner: Smurfit Westrock
Smurfit Westrock Packaging Machinery & Automation Group Gorleston’s fully automated right-size packaging system, Opera, is versatile with excellent monitoring, reducing waste through dedicated box sizes.
Innovative Processing System Non-FoodTechnology
Winner: Ystral
Ystral’s Anti-Fouling System for Fish Farm Nets stood out as a genuine innovation using multiple solutions to dramatically reduce process time and energy consumption.
Schubert UK’s automated pick & place infeed solution, the tog.519 cobot, is very useful for all industries, and for many applications where products are not sorted or in simple lines or cells on conveyors.
Innovative Processing System Multi-PurposeTechnology
Winner: Fortress Technology
Fortress Technology’s Multi-Machine Performance Validation Reporting Package demonstrated clear improvements in automated checking for metal detection.
Automate UK Awards 2024
Innovative Vision Solution
Winner: Scorpion Vision
Scorpion Vision’s innovative use of its technology to solve a real-world problem, removing meat from crustaceans, is a triumph with demonstrable productivity gains and cost savings as the end result.
Partnership of the Year
Winner: Jenton Dimaco
Jenton Dimaco impressed by demonstrating how three businesses improvised co-operation, found a way to dovetail different technologies, and reconcile a range of line speeds and protocols.
Lifetime Achievement
Winner: Colin Coules, Eco Pack Technologies
Colin Coules’ knowledge, customer service, enthusiasm, passion and commitment have never waned. He is quite simply an inspiration to everyone involved in the packaging industry!
Big Box Group’s XP15 Automation Robot is a unique, very practical, cost effective, and affordable robot navigation system.
Environmental Initiative of the Year
Winner: I-Mark UK
I-Mark has continually worked on improving its environmental footprint through the consistent process of monitoring impact and implementing positive change throughout its business practices.
Rising Star of the Year
Winner: Lewis Morley
Festo’s Lewis Morley stood out among the ‘rising stars’. His innovative and passionate approach has added significant value to the business. In addition, he helped to upskill colleagues and inspire the next generation.
Order Fulfilment Efficiency
L-A-C Logistics Automation combines expertise in warehouse automation and its partnership with Exotec to deliver the Skypod® system at iForce’s large-scale, multi-user 3PL facility in Northamptonshire.
Ideally suited to handle today’s 3PL operational challenges and utilising the latest innovative Autonomous Mobile Robot (AMR) technology, the Skypod® system delivers a fully scalable, future-proofed automation solution which drives efficiency and sustainable operationstonewlevels.
The Skypod® system utilises a high-density storage structure with totes containing items for customer order fulfilment, retrieved by a fleet of AMRs programmed to carry out order picking and replenishment tasks with exceptionallevelsofaccuracyandefficiency.
Through the installation at iForce, L-A-C showcases how collaboration, technology innovation, and system integration expertise united to provide iForce with an exceptional automated order picking and replenishment solution, with the agility, flexibility, and reliability they requiredtomanagetheirexpandingfulfilmentservices.
Integrated Systems for Seamless Operations
Furthermore, the Skypod® system works in parallel and in conjunction with other manual, robotic, and automation technologies within the warehouse, providing iForce with synchronised and seamless operations leading to greatly enhanced pick efficiency andaccuracy.
“In order to provide our clients with the best possible service in a competitive market, it’s vital for iForce to continue to invest in automation and the Skypod® system delivers everything we need in one compact and highlyefficientsolution.
The productivity benefits we are already seeing means that plans are in place for the system to be expanded further,asourclientbasecontinuestoexpand.” Business PlanningManager,iForce
iForce Installation was Nominated as Finalists for 3 Industry Awards in 2024 including Automate UK Awards, Supply Chain Excellence Awards and Robotics & Automation.
Why choose L-A-C?
L-A-Chasover25yearsofindustryexperiencedelivering automation solutions with core expertise in Robotics & Automation, ASRS, Conveyor Systems & Conveyor Modules. We provide innovative, tailored solutions from small systems to complex, large-scale projects, combined with best-in-class support and continuous improvement services, and are proud to manufacture our high-quality conveyorsintheUK.
UK INTEGRATION PARTNER OF THE SYSTEM
New Machinery
New combi inspection systems expand choice
Customers will have a wider range of options when sourcing the right combined inspection unit to suit their needs, says MettlerToledo Product Inspection, with its launch of two new systems integrating high-performing x-ray and metal detection technology.
The CM Combination system brings together the precision of the C-Series checkweigher and the company’s advanced M30 R-Series metal detector and offers an “optimised price-to-performance ratio”, it claims. C-Series checkweighers are said to deliver unparalleled accuracy and precision. The option of FlashCell load cell technology improves the ability to carry out checkweighing at higher product throughputs.
The M30 R-Series is equipped to detect a range of ferrous and non-ferrous contaminants, including aluminium and stainless steel, and can be optimised for both wet and dry applications.
C-Series checkweighers
The combination systems save on space and reduce total cost of ownership
feature in the CX Combination system, too, but this time twinned with Mettler-Toledo’s X2 Series x-ray inspection. The system builds in ContamPlus software, with its ability to run over 30 inspection algorithms continuously and in parallel, detecting hard-to-find foreign bodies while reducing waste.
X2 also boasts HiGain detector technology which, the company claims, generates sharper images to deliver outstanding contaminant
detection. These systems are capable of identifying a wide range of contaminants, including metal, glass, stone, calcified bone and highdensity plastics, while also performing quality assurance checks such as detecting missing or broken products.
Space optimisation, increased productivity and lower total cost of ownership all result from specifying these systems, says Mettler-Toledo.
T 0116 235 7070
W www.mt.com
Coffee bagging runs at 65 packs a minute with recyclable films
Syntegon has added the PMX 4001 vertical bagger to its range of equipment for packing both ground and whole coffee beans, taking proven PMX series technology on to a significantly smaller footprint.
“Aroma protection and quality remain crucial, especially for coffee,” says product manager Christina Holm. She adds that the ability of the machine to process alternative packaging materials at high outputs means that manufacturers can comply with the EU’s Packaging & Packaging Waste Regulation, due to take effect in 2030.
The system, which was introduced at Fachpack, Germany, will run at up to 65 x 500g bags per minute.
T
01332 626262
W www.syntegon.com
Haul of American launches includes variable data options for label converting and wider analogue print operations
Labelexpo Americas in early September saw Domino Printing Sciences launch new products, including the K300 monochrome inkjet printer, the N730i Integration Module digital print engine for flexo print lines, and a new hybrid press developed with Mark Andy.
The K300 builds on the track record of the K600 print bar, as a compact, flexible option for converters looking to add variable data capabilities to analogue printing lines.
Operating at up to 250m per minute, the K300 has also recently been used to code bottle tops.
“The industry move to
2D codes at the point of sale has led to an increase in demand for variable data printing, with many brands looking to incorporate complex 2D codes, such as QR codes powered by GS1, into their packaging and label designs,” explains senior product manager Alex Mountis.
Engineered to support label converters in delivering highresolution digital printing, including variable data, the N730i produces
up to 1200dpi print at high speeds. It allows converters to work with their preferred OEM partner and Domino to create a customised digital hybrid printing and finishing line.
The Chicago expo showcased the 1200dpi DSiQ-730 hybrid press developed with Mark Andy and bringing together flexographic and digital print, along with finishing, in one process.
T 01954 782551
W www.domino-uk.com
Degassing valves are recyclable
The K300 can build in variable data
New Machinery
Paper-packing line suits e-commerce operations
Hugo Beck has added the paper e-com rapid to its range of horizontal paper-wrapping machines for e-commerce, mail order and logistics applications.
It sits alongside the paper e-com fit, launched in 2023, and can achieve packing speeds of 900 cycles per hour, says the company. The machine creates packs with two sewn and two glued sides, automatically sizing the pack to the dimensions of the product, with a maximum height of 200mm.
Timo Kollmann, managing director at Hugo Beck, says that delivering sustainable packaging solutions with increased speed and efficiency is what drives innovation at the company, which is represented in the UK by Yorkshire Packaging Systems.
“Our goal is to future-proof our customers’ packaging processes through the integration of fully automated packaging machines like the paper e-com rapid,” he explains. “This helps
reduce downtime, improve product packaging quality, and enhance efficiency and sustainability.”
While the paper e-com fit selects one of two paper rolls of different widths, minimising paper use, the rapid achieves higher packaging speeds by utilising two identical paper webs.
In fact, both the rapid and the original paper e-com fit models are designed to use minimal paper while
packaging goods in an effective manner. These machines are suitable for the direct dispatch of individual or grouped items, says Beck, and can process both uncoated and coated recyclable papers.
The launch of the paper e-com rapid comes after a year of significant growth for Hugo Beck in the e-commerce, mail order, and logistics industry.
T 01484 715111
W www.yps.co.uk
The system builds in flexibility
Cradle attachment lifts film rolls from horizontal position
Packline has further extended its range with a suspended overhead cradle attachment, originally designed for a food industry customer needing to lift horizontally-stacked film rolls from a pallet, aided by electricpowered lift.
The attachment transfers rolls horizontally from the pallet via their core, using a mandrel. The rolls are transferred to the processing line, where the rolls are positioned in the top feed position on cantilever rollers. Adjustable hooks enable the attachment to cater for a variety of roll widths. The cradle attachment can be easily manually adjusted to lift rolls with a range of diameters. This is achieved by employing sliding suspended cradle arms. 01202 307700
T
W www.packline.co.uk
Tabletop and high-output continuous fryers are ideal for doughnuts and more, many boasting improved controls
European Process Plant (EPP) says it is now the exclusive UK and Ireland distributor of German equipment manufacturer Jufeba, which has a range of frying technologies for doughnuts and other deep-fried goods.
Options range from tabletop fryers to large-scale continuous lines.
“We’re delighted to be partnering with Jufeba, which is a high-quality and well-respected manufacturer renowned for its
craftsmanship,” says EPP managing director Steve Merritt. “Like EPP, Jufeba has more than 50 years of experience in the industry, which it uses to create exceptional solutions to solve industry challenges. It excels in automated doughnut frying technology, allowing bakers to offer diverse product ranges with enhanced speed, consistency and efficiency.”
The latest version of the company’s WW2-AT
doughnut fryer features a new 7-inch HMI touch panel. There is also an automatic lidclosing system for improved usability, as well as custom baking programmes with up
to three turning processes.
Jufeba’s USD 2.0 in line frying system now requires less oil, and features an automatic electronic oil level control as well as an automatic fat cleaning system, increasing the quality of baked goods and oil lifespan. The German company also manufactures supporting products and accessories including cream cookers, food warmers and automatic filling systems.
T 01372 745558
W www.eppltd.co.uk
Beck says it has seen a year of growth in demand for e-commerce systems
Jufeba is a specialist in doughnut frying
Applicator for linerless labels has reduced downtime requirements
Bizerba has launched the flexible, cost-efficient and sustainable PAS-I CleanCut linerless label applicator for tray-packed product, a fully-automated system which is said to simplify production processes.
Demand for sustainable labelling systems is particularly acute in the UK, says managing director Jonathan Forster, where it is driven by both consumer preferences and regulatory pressure.
“Our innovative labelling system addresses the pressing need for cost-effective, ecofriendly solutions in the UK’s competitive landscape,” he says. “The PAS-I CleanCut not only enhances operational efficiency but also supports our clients in their sustainability commitments, allowing them to meet both consumer expectations and environmental regulations.”
Different label styles can be applied
The system is able to process up to 120 labels per minute, says Bizerba, and is suitable for various tray types. It stands out for its low energy consumption and the complete elimination of liner waste, significantly reducing both environmental impact and disposal costs. With its increased roll capacity and patented CleanCut technology to prevent adhesive residue on blades, downtime is minimised as rolls require changing and blades cleaning far less often.
T 01908 682740
W www.bizerba.com
A one-stop solution for all futureoriented packaging concepts
SOMIC has created a one-stop solution for all future-oriented packaging concepts with the new 434 series. It has been cleverly engineered to cater for tray packaging, tray-cover or wraparound solutions. Based on
proven, tested and standardised function groups, it offers maximum performance on a compact footprint.
For more information call 01256 467177 or visit somic-packaging.co.uk
Installation News
Colombian plant includes 54,000 bph hot-fill block
Colombia’s largest soft drink producer Postobón has acquired three PET filling lines from KHS in quick succession over the last few years.
The most recent, installed in 2023, is a TriBlock for carbonated beverages such as Pepsi Cola, as well as water. It includes a roll-fed station for hot-melt wraparound labelling, with a maximum output of 54,000 bottles per hour (bph). Formats span 300, 400 and 600ml, 1 and 1.5 litres – plus 2.5 litres, a size that is very popular in Colombia.
National project manager at Postobón César Bohórquez says his team has been impressed by the supplier’s “pioneering technological standards” for high-speed lines.
The second turnkey line, which has been operational since 2021 (like the first, in Bogotá), is built around a BloFill duo block for the hotfilling (using HotFill+ technology) of juice, tea and energy drinks, with optional nitrogen dosing. This also
runs at speeds up to 54,000 bph, and is said to be the fastest KHS line of its type worldwide.
“With the new HotFill+ line from KHS we can boost our production of juice, tea and energy drinks by up to 54%,” says Bohórquez.
Before that, the first of the three lines included an InnoPET TriBlock for water in
plastics, comprising a stretch blow moulder, labeller and filler, also with a maximum capacity of 54,000 bph.
In the dry section of this line, the multifuel burner on the Innopack Kisters SP enables the shrink tunnel to be heated by either natural or propane gas.
T 0121 713 6900
W www.khs.com
Palletising is much more efficient
Animal feed factory improves efficiency with robot palletiser
Chestnutt Animal Feeds in Northern Ireland has taken delivery of a robot palletiser from automation supplier RMGroup, with benefits in terms of efficiency and quality.
The supplier explains that the Quick Pal 1 Robot Palletiser offers a compact and robust design, the ability to handle a range of formats and weights, as well as user-friendly controls for speedy pallet pattern adjustment.
“Integrating the palletiser into our operations has not only increased our efficiency but also ensures the consistent quality of our packaging process,” says managing director James Chestnutt. “Partnering with RMGroup has been a seamless experience and their expertise has been invaluable in helping us achieve our operational goals.”
T
01686 621704
W www.rmgroupuk.com
• Dustless conveying of pharmaceuticals, dry powder, chemicals, free flowing granular produce, food materials and plastics
• Clean, safe, compressed air driven multistage vacuum pump, pre delivery ATEX approval upon request
• High quality polished 304/316 stainless steel construction
• Minimal maintenance with self-cleaning filtration yet high level of capacity, from 0.4TPH – 9.0TPH
• Compact design more suitable for low head height environments
The InnoPET BloFill block uses HotFill+ technology for the highest speeds
Wine bottler fits nearly 200 sensors into facility
Greencroft Bottling has created a new wine storage and filling facility, with future capacity of up to 400 million litres per year, which incorporates nearly 200 sensors from ifm electronic – chiefly pressure and level sensors – and some 100 IO-Link masters, along with five light towers.
The new plant comprises a wine intake system, storage, CIP facilities, water services and filtration apparatus, all controlled by a customdesigned SCADA system. This system, with its graphical user interface, relies on accurate data from the plant, which is where the abundance of sensor technology comes in.
The choice of ifm, says the component supplier, is to do with a number of factors: its comprehensive range of competitively-priced sensors; the fact that they support IO-Link technology, a digital communication system optimised for use with sensors and actuators in industrial environments;
Case-packers
and the engineering supplier’s knowledge and experience of ifm sensors and their performance.
Future-proofing the facility was a key priority for the customer. Greencroft engineering project manager Daryl Whalen-Griffiths says: “As Greencroft Two is a newbuild project, it provided us with a blank slate and therefore the opportunity to be bolder in our design, including elements we don’t
necessarily need now but will do in the future to enable our business to grow.”
Level and pressure sensors are complemented by temperature, conductivity and flow sensors, along with standard inductive sensors, which are used in the plant’s tanker bays.
Design and engineering in the plant was provided by ABM.
T 020 8213 0000
W www.ifm.com/uk
Multiple robots pick and place chocolate batons into cartons
Sweet Candy Company in Salt Lake City, USA, recently installed a fully-automated system from Schubert to pack its Chocolate Sticks into trays.
The Pickerline includes 16 vision-guided F4 SCARA-type robots grouping product, with further robots placing one layer of up to 17 sticks into each tray, followed by a layer sheet, a second tier of product and a lid.
“From the initial project planning to the currently ongoing operator training, Schubert has provided everything we’ve expected,” says president and owner of the candy company Rick Kay.
The semi-automated equipment formerly in place could not cope with volume increases, Schubert explains.
01676 525825
W www.schubert.group/en
automate manual loading of diverse primary pack formats while avoiding damage and unnecessary cost
Sidel has delivered three adapted wraparound casepackers to Miswa Chemicals in the UK, handling different types of homecare, automotive and insecticide packaging, with flexibility and cost as priorities.
The customer wanted to replace the manual packing of large metal cans, jerrycans and aerosols into preformed corrugated cases.
“Sidel was one of the very few companies capable of addressing our diverse
primary and secondary requirements with technically and economically adapted solutions from their existing proof-ready portfolio,” says Miswa director Oren Patel-Champion.
For a metal aerosol spray range, Sidel proposed the Cermex WB46 wraparound case-packer. As well as using less board, says Sidel, the system provides a shelfready option, thanks to pre-scored panels built into the wraparound blank. Miswa
runs the WB46 at around nine cases per minute, but the system is capable of speeds up to 28 cases per minute.
The line producing large 3 and 4.5-litre metal cans of
filler paste avoids any risk of pack damage from pickand-place by instead utilising the Cermex SF39 automatic bottom-load case-packer. The machine can produce six-to-10 cases per minute. Where changeover is required, only mechanical adjustment is needed, with no change parts.
Another line, handling 5-litre jerrycans, has a second SF39 case-packer, this time managing 12 cases per minute.
T 01707 292820
W www.sidel.com
Smart sensors are used throughout, including in the filtration skid, shown here
Miswa moved to wraparound cases
High-humidity storage keeps par-baked goods for 10 days
Food cups
Your ingredients for successful automation
• Detectable suction cups
• FDA and EU compliant
• Wide range of shapes and sizes
Abakery in the north of England has acquired the first MIWE smartfresh storage system from European Process Plant (EPP), allowing it to store goods for longer, and so operate more efficiently.
According to EPP, the system means its customer can store par-baked goods, such as bread, for a longer period of three to 10 days, and bake them off as and when they are needed.
Temperature and humidity are key
Stored at a constant temperature of about 4°C and a humidity of 95-98% RH, says EPP, par-baked goods are able to absorb more moisture with each day they are stored. This improves the texture, flavour and shelf-life of products, it adds.
• Suitable for different food objects from bread, fruits and pralines to frozen, raw or prepared foods.
www.piab.com info-uk@piab.com 01509 857010
“MIWE’s smartfresh is a fantastic new innovation in storage technology, allowing bakers to offer customers the best possible quality and freshness, whilst also preventing wastage and saving time, money and energy,” says Steve Merritt, managing director of EPP, exclusive UK and Ireland distributor for MIWE.
“It’s especially well-suited to bakers with a wide variety of single par-baked goods.”
T 01372 745558
W www.eppltd.co.uk
Multipack system boosts can range
As part of a £2 million investment in a new canning line, soft drinks manufacturer Belvoir Farm has installed an Automatic Beverage Multipack Machine from T Freemantle, boasting multiple options when it comes to individual can sizes and cans-per-pack.
In 2022, the Leicestershire company brought its outsourced can filling in-house.
“Our canned portfolio was growing at such a pace that we needed to invest in in-house production. Up until that point, we hadn’t truly committed to the category,” says Martin
Reynolds, head of engineering and project leader.
Belvoir cans products in 150ml, 250ml and 330ml volumes. In terms of multipacks, it has introduced 4 x 330ml slim can and 6 x 150ml mixer can collations.
“T Freemantle confirmed everything we were hoping to hear – that their machine could handle all of the can formats we were hoping to run as well as those we might want to introduce in the future, such as 10 or 24 can multipacks for export markets,” says Reynolds.
T 01724 276908
W www.tfreemantle.com
Cobot takes on screwdriver job
UK company
Panorama Antennas has automated a repetitive assembly task by combining a Universal Robots cobot with a Robotiq Screwdriving Solution, both sourced from RARUK Automation and integrated by Vikaso.
The antenna and wireless technology manufacturer chose the UR5e cobot arm, the second-smallest cobot model in Universal Robots’ range of 6-axis robotic arms, with a payload capacity of 5 kg. Vikaso provided its V-CAP URCap software plug-in and V-EYE remote access and monitoring solution, which includes a camera module.
“The primary reason for integrating a robotic arm into the assembly process was to increase quality through a uniform, repetitive assembly process, whilst at the same time enabling the company to redeploy the assembly operators to higher skilled tasks such as soldering,
connector assembly or RF testing,” explains Mark Jesman, operations and supply director at Panorama.
The UR5e is said to be the ideal choice for low-weight collaborative processes such as pick-and-place or screwdriving, and its small footprint makes it easy to integrate into existing production set-ups.
W www.rarukautomation.com
W www.universal-robots.com
W www.vikaso.co.uk
The Automatic Beverage Multipack Machine operates with various can sizes
Robotiq supplied the screwdriving system
AS FAR AS YOUR EYES CAN SEE: INFINITE OPTIONS FOR PACKAGING FOOD. BROUGHT TO LIFE WITH SCHUBERT.
Being flexible is good, being fast and flexible is even better. Schubert packaging machines are leading the way. Intelligent control and precise robotics can now replace complex mechanics to ensure maximum flexibility in all packaging processes. In fact, 80% of the leading FMCG companies count on us and our flawless packaging combined with the lowest possible consumption. In line with our Mission Blue Sustainability Initiative: A winning proposition – for our planet and for you. www.schubert.group/en/food.html
Installation News
Show innovations provide valued access to products PPMA Show Review – intro
September saw a larger PPMA Show return to Birmingham’s NEC with a number of overlapping innovations in the staging of the event helping to provide improved access and information to visitors, particularly where the spotlight fell on new products.
Across the show, 11 exhibitors were able to showcase the launches they were most proud of as part of the Innovations Eleven feature. This combined a live demonstration of each piece of technology, beamed to screens around the show, with an in-depth interview about the product in question.
Separately, an Innovation Tour took interested visitors on an itinerary around the 11 participating companies to hear more about these innovations and to ask questions.
Over 20 show visitors took part in the first day’s Innovation Tour. At least one engineer from a major drinks brand-owner returned to a featured stand and set up
a visit to one of the company’s Scottish distilleries. Others returned to a couple of the stands to talk about labellers and coding.
But all around the show, visitors were turning curiosity into firm leads. Overall, they were pleased with the event, as they told the PPMA TV team. “It’s insightful,” one said. “You think you know the industry, but there’s always something new to learn.”
Another said: “Who knows what you’ll stumble across while you’re looking for something else?”
Exhibitors, too, were extremely happy with the string of show innovations and with the three days as a whole. “It’s a showcase event,” GEA head of sales Nigel Adams told the TV team. “We cannot not be here.”
T 020 8773 8111
W www.ppmashow.co.uk
Case-coding system makes its mark with visitors to the show
Engelmann & Buckham (E&B) was among the exhibitors benefitting from the Innovations Eleven showcase and tour, providing the perfect launchpad for Norwix Marking Systems’ UC22 Ink Jet Case Coder.
According to E&B, visitors responded positively to the coder’s potential to streamline operations and reduce costs.
“We are thrilled with the response to the UC22,” said Norwix sales and marketing director Martin French.
“We knew there was a need for more flexible and cost-efficient case-coding solutions, but the overwhelming interest at the PPMA Show confirmed just how valuable this technology is.”
INCOMING ORDERS
A publishing company, a healthcare provider and a contract packer placed orders at the show, while several additional orders were still in negotiation in the second half of October. Being part of Innovations Eleven meant E&B was able to carry out live demonstrations from its stand, showing details such as ink cartridge replacement.
T 01420 593680
W www.buckham.co.uk
Insights from Huel and Innocent Drinks map out routes factoring in carbon footprint of product and packaging
One of the two keynote speakers at the show, Jessica Sansom of plant-based meal supplement brand Huel, provided insights into the relationship between nutrition, packaging and wider sustainability.
As sustainability director, she was well-placed to tackle the topic, saying: “Our planet is not healthy. We’re not healthy. We can’t look at the two things in isolation. We can’t put Health over here and Sustainability over there.
plastics pouch, given that only some 3% of overall carbon footprint comes from packaging.
“We looked at recyclable alternatives, and all of them involved a massive increase in that footprint,” she said.
Sansom compared her experience at Innocent Drinks a few years ago, where
products were at one point filled into a compostable biopolymer bottle. “In fact, more than 80% of local authorities collect and recycle PET,” she pointed out. There was another brief, if misguided, foray into 100% recycled PET, when a major drawback became the visual appeal of the bottle, prompting a fall in sales.
Like many brands, Innocent aimed for a compromise, with around 50% recycled content.
How can we stop thinking inside our silos?” She made no apologies for the brand’s multilayer
Engelmann & Buckham being interviewed about its Innovations Eleven product
Sansom gives a live interview after her keynote speech
PPMA Show Review
Metal detector attracts visitor interest at show
MDS showed the PH210 metal detector from Italian equipment manufacturer Ceia for the first time at the September show, demonstrating its much-improved sensitivity and other elements that make it especially suited to the pharmaceutical and nutraceutical market.
Describing Ceia as the “global benchmark for industrial metal detection systems”, the UK and Ireland distributor explains that the PH210 has been undergoing betatesting with customers. It is the first of the company’s metal detectors to have a separate captive touchscreen, says MDS sales director David Hale, designed for simplicity with an accessible user interface.
“The response at the PPMA Show was excellent and the new detector has gained lots of positive interest,” he adds. “We are in the process of
Levels of sensitivity have increased by up to 50%
following the new enquires generated and without doubt the new PH210 will be a great success.”
Key features include improvements to the PH210’s efficiency, including an increase of up to 50% in
sensitivity, in terms of the size of metal fragments that can be detected, says MDS. The embedded network controller and data logger PC, which were an option on previous models, now come as standard.
The system comes with a fully digital electronic structure, new improved multi-point auto-learn function, auto-test function and automatic QC control function to increase productivity and save on downtime.
It is fully compliant with FDA code 21 Part 11, says MDS, and can store up to one million events for data integrity verification.
In terms of construction, the PH210 uses AISI 316L stainless steel throughout, and the ergonomic frame design is supplied with new anti-static castors for extra stability and ease of movement.
W 0161 286 8750
W www.mds.org.uk
Compact cobot sees higher food industry sales, says supplier
Alongside the robotic ultrasonic cutting system on its stand, newtech’s space-efficient pick-and-place cobot received plenty of visitor attention.
“Real momentum behind sales of newtech’s cobot systems has started to build this year,” says sales and service manager Tara Allston. “For the food industry, currently, it’s mostly used for packing and palletising, but the cobot is flexible, and can move between different applications.”
The ABB cobot, which can be equipped with vision, is produced to an IP67 standard or higher, and is often deployed in other industries. “It’s simple to programme, using the Easy Wizard programming language, and payback periods are usually less than two years,” she says.
T 01234 783680
W www.newtech-ltd.co.uk
AM Labels reports that the most popular systems at the PPMA Show proved to be its selection of automation equipment, including the fully-automatic LabelPack Label X JR applicator.
“To highlight its versatility, AM Labels demonstrated how the Label X JR applied labels when connected to a dedicated packet-feeding system,” says sales and marketing manager Brendon Bass. The idea was to show how a wipe-on applicator can support
businesses in accelerating operations and increasing efficiency, he adds.
The Label X JR applicator is designed for labels with a
full range of its technologies
maximum width of 140 mm and lengths of up to 350 mm. It can accommodate label rolls up to 300mm in diameter. Different versions of the
Label X JR are available, as well as optional stands to facilitate a range of applications, says AM. Also on the stand was the recently-introduced Epson ColorWorks C8000, boasting print speeds of up to 300mm a second, the LabelPack Panda print-and-apply system and the Afinia X350 digital roll-to-roll label press.
The X350’s Memjet DuraFlex technology can achieve a resolution of 1,600 x 1,600 dpi.
T 01536 414222
W www.amlabels.co.uk
The AM Labels stand managed to fit in the
Nestlé expert shares experiences of ‘paperisation’ and digital print
Innovation lead at Nestlé Stefan Casey delivered the first of the show’s two keynotes, and his punchy presentation on ‘digital transformation’ did not disappoint.
The ‘paperisation’ of confectionery packaging figured prominently.
One example was the shortlived, nut-based Yes! bar.
“It was the first time packaging could say to product, ‘You need to make your product better’,” he recalled.
There are multiple barrier papers on the market now, Casey stated, but the art of printing on to the substrate has, in many cases, been forgotten.
Casey is specialised in confectionery
“I was doing 35-hour print trials to get the packaging through machines that were older than me,” he told the audience. “We’re entering a world where material changes are here to stay.”
He pointed to a personalised digital print project with KitKat. “It was the first time on coldseal flow-wrap,” he said, “with up to 500,000 sent out around the UK. But it was ahead of its time, and the supply-chain facilitation wasn’t there.” Part of this involved the need to vet images submitted by the public.
“Now, with AI, it may work.”
Our service team is always on hand to help
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NEW SUPPLIER ANNOUNCEMENT
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Leak and Flow Testers Precision Metering Pumps
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Tel: 01256 766003 Web: www.fillers.co.uk
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Cody Technology Park, Farnborough, GU14 0LX
PPMA Show Review
Rentals open up machine options
Automated end-of-line packing equipment
supplier Pace Mechanical Handling launched a new rental service at this year’s PPMA Show.
Over recent months, the company says it has responded to several enquiries from companies looking to overcome short-term challenges such as recruitment difficulties and seasonal increases in volumes.
The rental option applies to all of Pace’s product line, which includes the Gemini twin-head weigher, Orion Weigher, Orion Weigher and sack placer, CBC sack placer and stitcher line, as well as the new PacePal collaborative robot.
“There are many benefits to renting rather than buying,” says managing director Nick Cesare. “Most significantly, the upfront cost is a lot lower than buying, which allows people to access automated and robotic solutions without needing a lot of capital. With just a three-month minimum
term, people can overcome seasonal increases in demand or short-term contracts that temporarily increase their throughput requirements.”
The company insists it offers the same “exceptional” level of customer support to rental clients as to those buying the equipment outright, including operator training, software updates and servicing throughout the term of the agreement.
Input costs such as energy and wages have restricted customers’ finances over the past year, Pace adds.
T 01775 630900
W www.robotpalletizing.co.uk
From wrapping to e-commerce
Yorkshire Packaging Systems (YPS) featured e-commerce bagging, packaging materials and two very different shrink-wrap machine options on its stand at the show.
For display applications, there was an automatic L-sealer, which produces glossy, wrinkle-free, shelfready packaging. The model displayed featured a servodriven sealing jaw for precise movement, designed to increase line speed while achieving an excellent aesthetic finish.
A side-feed sleeve-wrapper, said to be ideal for transit wrapping applications, was also on show. This flexible system can wrap multipacks or singles, trayed or trayless collations, with minimal disruption when changing between pack types, says YPS.
Joining the two shrinkwrappers were two vertical bagging machines, able to maximise throughput for operations preparing products for mailing. Advanced
onboard technology included integrated data banks, labellers, scanners, and printers (including direct on-bag printing) for a secure all-in-one process. Versatility was demonstrated by the fact that one vertical machine was running paper, the other polybags.
Separately, a new display underlined the range of films and other e-commerce bagging options available and held in stock in the company’s large warehouse.
T 01484 715111 W www.yps.co.uk
Cesare underscores rental benefits
Shrink-wrap featured on the stand
Platforms reduce kit requirements
Promtek chose to showcase its Condor Cloud and MicroMan cloud-based control systems, designed to offer intelligent weighing management, recipe handling and production monitoring.
Condor Cloud provides IT/OT integration for ingredient and recipe handling without the need for expensive IT infrastructure such as on-site servers, says Promtek, making it ideal for smaller, fastgrowing manufacturers with a weighing process. Browserbased Condor Cloud will help grow a business, reduce costs, and optimise production facilities, it adds, without the need for overly complicated software or paper trails.
MicroMan is a hand weighing platform which collates ingredient and recipe information from manual additions, as part of a bigger batch using either Promtek’s signature process control platform StoraWeigh or the integration platform Condor, to generate bespoke
Customised systems can be supplied
production control and data.
Customised solutions include one recently created in conjunction with Schneider Electric using its Tesys system, explains marketing manager Lani Scholtz. “We were able to set up a system where a feed mill’s machinery was completely controlled and monitored via a network connection, without the need for contactors or a costly PLC,” she says.
T 01782 375600
W www.promtek.com
Film system meets e-commerce needs
Springpack demonstrated the versatility of the Buzz’n’Pack system from German machine manufacturer Emba-Protec, for secure semiautomatic packing of goods in e-commerce and other sectors.
Capable of up to four cycles per minute, the system uses film to secure product to any one of four sizes of base tray, which can then be inserted into a case or carton. According to Springpack, it offers a swift and consistent packing process every time, regardless of the operator, and eliminates variable material consumption. Film costs are included in the tray price, it says.
Operators can switch between the four standard base sizes in just seconds, without the need for programming, and operator
training is said to take a matter of minutes.
The machine will run recycled-content film with up to 65% recycled material, says the UK distributor, aligning with companies’ sustainability goals. It describes Buzz ‘n’ Pack as a ‘plug-and-play’ device, requiring no highvoltage current or compressed air, further simplifying installation and operation. An additional advantage of the system, Springpack explains, is its compact footprint.
T 01905 457000
W www.springpack.co.uk
TOP TAMPER EVIDENCE
Hot melt and cold glue application by Robatech is your guarantee for maximum protection against product manipulation and safe sealing of folding cartons.
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The machine wraps up to four trays per minute
Nitrogen skid generates gas with low oxygen content for food use
HPC launched a new nitrogen gas skid for the food and beverage industry, the N₂PAC, allowing manufacturers to generate the gas on-site and so avoid the cost and logistical challenges of relying on third-party deliveries.
Customers are said to benefit from cost savings of up to 90%, compared to buying in high pressure cylinders.
The integrated system includes a refrigeration air dryer, pre-filtration package, oil vapour reduction filter (to Class 1), N₂ generator, buffer vessel and sterile process filter, providing what it calls a ‘plug-and-play’ option for manufacturers.
The system is compact but scalable
N₂PAC can deliver nitrogen with an ultra-low 0.5% oxygen content, with the advanced filtration system ensuring broader gas purity, and allows real-time monitoring of that purity and of gas output.
The design is compact, scalable and modular, says HPC. Nitrogen quality is said to be third-party validated and certified to European EIGA statute 231/2012 for gas used as a food additive, E941, as well as being FDA and Pharmacopoeia compliant.
T 0845 430 0472
W www.hpccompressors.co.uk
PPMA Show Review
Industrial PC platform can streamline control
Beckhoff UK
shone the innovation spotlight on its industrial PC (IPC) platform, said to be powerful enough to consolidate all packaging and processing steps in a single, unified system as a prime example of its options for modular, flexible control.
According to the company, the IPC represents a major advance for production managers and control engineers seeking to streamline operations and reduce system complexity.
This single PC “for all packaging processing steps” is able to integrate tasks such as motion control, vision, robotics and data-handling into one centralised location, says Beckhoff, eliminating the need for multiple specialised controllers. This can simplify the architecture and reduce costs, it adds, enhancing
performance by ensuring greater synchronisation across all stages of the process, leading to higher throughput and improved product quality.
Another focus for the company was the MX-System, a modular automation platform that does away with the need for traditional control cabinets. This system is said to integrate all necessary automation functions into a compact, IP67-rated design which can be mounted directly onto machines. For machine builders, this represents a
breakthrough in reducing installation time and cost, Beckhoff states, while also providing unparalleled flexibility in machine layout.
In addition, Beckhoff UK showed its stainless-steel automation components, specifically designed for industries with stringent hygiene requirements. These components are said to be ideal for the food and pharmaceutical sectors where cleanliness is crucial.
T 01491 410539
W www.beckhoff.co.uk
UV laser is capable of coding on tricky polymer substrates
Latest coding and marking systems demonstrated by Markem-Imaje included the SmartLase UV500, Super Piezo Inkjet (SPI) technology and thermal transfer overprinting.
The UV500 is the company’s newest UV laser coding technology. The 5-watt laser delivers the most precise, high-quality coding on difficult materials such as thinner monopolymer films, polymer labels and thermoplastics such as HDPE. Also shown was what it calls its most advanced CO2 laser coder, the SmartLase C600, said to offer exceptional performance in high-speed applications.
The Markem-Imaje SPI system satisfies demand for GS1-compliant 1D and 2D codes and combines assets of continuous inkjet and drop-on-demand.
T 0161 864 8111
W www.markem-imaje.com
The MX-System is said to do away with the need for traditional machine control cabinets
The SmartLase UV500 is flexible
PPMA Show Review
Live sessions thrash out thorny issues surrounding automation
Panel events at the Show included a BARA discussion around driving out manufacturing inefficiencies and the UK Automation Forum’s latest roundtable asking what might persuade the food industry to adopt more robots.
In both cases, Gail Hunt steered an authoritative group of industry experts through a lively and revealing debate.
The BARA discussion heard from outgoing BARA chair George Thompson of Güdel, incoming BARA chair Oliver Selby of Fanuc UK, Andrew Mason of RARUK Automation and Dr Martin Kidman of Sick UK. But how to bring the customer’s leadership team onboard with automation?
“Have an automation strategy that fits with the manufacturing and business strategy,” Selby advised. In terms of limiting risk, he and others pointed to BARA’s new integrator programme.
Kidman stated: “It’s about understanding your current business before jumping in
with both feet.”
Mason emphasised the accumulated experience of suppliers and integrators.
“Other people will have been on the same journey,” he said.
“Only 75% of your application may have been done before, but that’s still a good 75%.”
Asked whether ‘overautomation’ was a risk, Thompson said: “There may be a risk of doing too much too fast. You need an overall strategy.”
The UK Automation Forum
brought together Martin Miller of Greggs, John Quinn of Marks & Spencer, Susannah King of Aquitech, James Causebrook of Automate UK and Grunwald and Rosie Davies of Reeco Automation. Quizzed about manufacturer reluctance to automate, Quinn said: “There’s seen to be a lack of skills to even start the process, to install and maintain equipment.”
Davies underlined
challenges from a supplier perspective. “You can prove your concept with simulations and trials,” she explained. “But before you know it, your key contact has moved on, and you have to start the process again.”
In Causebrook’s view, the emphasis should fall on improving provision of fulllife service. “The technology, too, needs to be as easy to use as a smartphone,” he told the audience. “As engineers – as an industry – we need to improve the soft-skill elements.”
The message from Greggs was clear. “The first thing I’d ask is, show me a factory where this kit has worked for five years, and where I can talk to the engineers,” said Miller.
Brexit, said Causebrook, was “an espresso shot” for UK automation. But King added: “We’ve still got a lot of catching up to do.”
W automate-uk.com/ our-associations/bara/ W ukautomationforum.com
Spanish company highlights compact machinery range both for sachet form-fill-seal and rotary premade pouch-handling
Spanish company Mespack played a key role in the show exhibit on the Acer stand, where its MLC and RM series machines were given a strong showing.
The MLC series consists of high-speed, small-footprint machines designed for producing large-format sachets. The system can reach speeds of up to 2,400 sachets per minute using a continuous sealing system, hence making it ideal for high-volume production in industries
such as pharmaceuticals, food, and personal care, says Mespack. The MLC series
is available in two models: the MLC1000 and the MLC1200, both controlled by the company’s Athena software. When it comes to rotary systems for premade pouches, Mespack has the RM series, with the focus on its fiveminute changeover capability, reducing downtime and boosting productivity.
Speeds of up to 60 pouches
per minute are possible, and the machines are compatible with various pouch formats, including the 3-sided seal, 4-sided seal, and stand-up pouch.
Some machines in the range are especially compact, with the RM260SC, for example, occupying just 8.5 square metres.
Also well-represented on the Acer stand were Tkmatik and UET Bernd Siebler.
T 01420 627137
W acermachinerysolutions.co.uk
Acer’s Emma Ridgway with the Mespack team
The UK Automation Forum got its teeth into the food industry and robotics
Installation News
Rethink lends new shape to cartoning and sleeving
Visitors to the T Freemantle stand were able to see how the company has engineered its new range of eight ‘ultraclean’ cartoning and sleeving systems to ensure they not only offer higher output, and greater flexibility – but also lower capital cost.
The next-generation fleet is the result of an 18-month R&D re-engineering programme and incorporates the latest components and advances in automation, simplified engineering techniques and an open-access machine frame design. The streamlined engineering has resulted in a 15% lower capital cost, says sales director Simon Holt.
“The marketplace for product manufacturing is ever more competitive,” he says. “For food and drink manufacturers to compete, line productivity must continually improve – so the onus is on OEMs to provide self-sufficient equipment with increased visibility, flexibility and output.”
Holt outlines the ways in which the machines improve productivity. “The new models are four-times faster to clean down, more self-sufficient to free up the operator, designed with universal parts for optimum uptime, and run multiple product formats without needing changeparts,” he explains.
The company says its philosophy focuses on making customers’ lives easier. It achieves this, it adds, by building machines into stock for express shipping, giving
Almost 50 years of experience in the personal care, cosmetic and pharma sectors.
Tamper
Polybags
BAMA compliant aerosol wrapping machinery
a guaranteed delivery time and offering value-for-money technology.
The range includes: topload and end-load cartoners (for multiple sectors); semiand fully-automatic beverage multipack machines (for bottles and cans); wraparound sleevers (for items including pizza, cosmetics, beverages and household items); and the Tray Case Packer, for larger pack quantities, which made its PPMA Show debut.
T 01724 276908
W www.tfreemantle.com
Looking beyond x-ray to plastics detection using vision led by AI
At this year’s PPMA Show, Fortress Technology Europe took the opportunity to provide insights, not only into its current food inspection ranges, but also into options for the future.
Sales director Phil Brown explained the company was expanding its portfolio to target hard-to-detect contaminants such as plastics. “We’re in the process of bringing to market a system to detect plastics,” he said, suggesting that the launch would happen before the end of the year. “It’s primarily vision-based, and uses AI.”
Pride of place on the Fortress stand went to the Icon X-ray system, with what the company called its “unmatchable processing and detection power”.
T 01295 256266
W fortresstechnology.co.uk
Singles, multipacks and collations can be accommodated
Trayed and trayless options
Icon X-ray running at the show
The Freemantle cartoning and sleeving range has been fully re-engineered
Installation News
PPMA Show Review
More than just robot and cobot palletising
Sidel presented a range of options to help with improving line performance, reducing downtime and cutting operational costs, highlighting its advanced automation including the RoboAccess_Pal S and CoboAccess_Pal to replace manual palletising.
‘Agility’ was the key concept at the show, whichever part of the food, home, and personal care (FHPC) sector it is applied to, alongside largerscale turnkey packaging configurations.
“Improving line performance is no easy task,” sales account manager for FHPC UK Bastien Carcenac admits. “But Sidel’s solutions can help manufacturers reduce downtime and operational costs while adapting to market demands –supercharging efficiency.”
The RoboAccess_Pal S can handle up to 2,400 products per hour, delivering high performance and flexibility in a compact footprint, he explains. This system
maximises space utilisation while achieving speeds of up to 12 cycles per minute and lifting a payload of up to 25kg. Sidel says it combines the best of robot and cobot technologies.
The CoboAccess_Pal is described as enhancing working conditions while maintaining high safety standards. Here, different kinds of cobot can be integrated to manage payloads up to 19kg.
Both systems offer payback typically in one-to-two years, says Sidel, by optimising the end-of-line packaging process.
“Sidel’s offerings cover
all aspects of the packaging process, from PET blowing to filling, labelling, packing, and palletising,” Carcenac adds.
“This integrated approach enables Sidel to deliver tailored solutions that meet the unique needs of each client’s packaging requirements, space constraints, and production speeds.”
As a single supplier of advanced packaging technologies, the company claims it can ensure seamless system integration with its complete lines, optimising overall production efficiency.
T 01707 292820
W www.sidel.com
Precision couplings span elastomer and disc custom options
Alongside its latest planetary gearboxes, Apex Dynamics saw the PPMA Show as an opportunity to launch its first range of zero-backlash disc and elastomer couplings.
General manager Andrew Parsons says the company came to the show with a stronger product offering than ever, and has seen huge interest in the couplings range.
According to Apex, customers report often struggling to source couplings for a project, either because the size and range needed is not available, or because delivery times are poor.
The company says it can now supply the right size and quality of coupling, machined to the correct specifications, within its guaranteed 2-3 weeks delivery time.
T 0121 227 5340
W www.apexdynauk.com
Latest addition to thermoforming range joins VFFS as well as process systems from drum forming for meat to bakery
GEA aimed to delight visitors to its stand with its processing and packaging systems – and firsthand reports suggest it succeeded, not least with the new extension to its PowerPak line of thermoforming machines.
According to the company, the PowerPak 1000, shown here for the first time in the UK, epitomises efficiency, package quality and safety. It also offers improved productivity and significantly reduced operating costs.
GEA claims the compact system is ideal for startups and mediumsized businesses. It has a capacity of up to eight cycles per minute for products such as meats, cheese, seafood, dairy and fresh produce.
For vertical formfill-seal (VFFS), the company showed its SmartPacker CX400. It describes this as being exceptionally reliable
and designed for high bagging capacity, for example for confectionery and savoury
snacks, bagged salads and grated cheese. Food processing options on the stand included GEA’s highvolume drum forming machine, the Maxiformer 600. This gave visitors the opportunity to learn about the step filling process, which is said to reduce waste and ensure perfectly uniform meat products time and time again.
T 01908 513500
W www.gea.com/en
The company has extended its PowerPak thermoform range
The Apex Dynamics PPMA team
At the show, Sidel emphasised its abilities in supplying complete turnkey lines
Despite tough competition from overseas, the UK pharmaceuticals industry continues to demonstrate resilience, with automation as a major facilitator not just of efficiency but also – critically – of the highest standards of safety, hygiene and precision.
According to data provider Statista, projected revenue for the UK pharma market was expected to reach $31.26 billion in 2024. It predicts compound annual growth (CAGR) of 5.7% between 2024 and 2029. If, as forecast, revenue reaches $41.34bn by 2029, it will be approximately twice the size, in revenue terms, as it was in 2017.
Statista’s analysis identifies growing interest among the UK population in personalised medicine tailored to specific conditions. This track is supported by the dynamic pharma R&D sector, which serves to reinforce the wider life sciences industry.
Also backed by considerable R&D efforts is the medical device industry, complementing pharmaceuticals and often creating common ground between packaging and dispensing.
At the alternative end of the spectrum, ‘natural’, plant-based and nutritional supplement segments remain strong in the UK, typically with lower-volume production requirements, but just as likely to benefit from automation.
AGILE BUT NOT FRAGILE
The trend towards personalised medicine and the traceability of individual doses is a theme picked up by Domino over the next few pages of this feature. Other Automate UK members providing insights into the industry include Schneider Electric, which emphasises the relationship between ‘agility’ across the sector and digitalisation.
The company’s industry
The case for digitalisation
Pharmaceuticals may be set on personalisation, but Schneider Electric prefers to talk about digitalisation
marketing director
Chris Haines underlines the importance to pharmaceuticals, at every stage, of precision and compliance. “Unlike other sectors, pharma manufacturers do not have the luxury of constantly changing elements of the process to reach the best level of efficiency,” he says. “Therefore, agility within pharmaceutical facilities looks
different to other industries. As each and every process in pharmaceutical production is tested and validated, and manufacturers must follow standardised protocols to ensure that there are no bad batches.”
On one level, agility can take the form of software adaptability. “Batch management software allows a manufacturer to change
For this supplier, the concept of ‘agility’ extends throughout the entire lifecycle of a facility
the makeup of its products without making any changes to the control system hardware or coding,” says Haines.
Robotics clearly has a strong role to play in the sector, not least in mitigating its regulatory challenges. Schneider Electric claims the International Data Corporation puts the proportion of life science businesses saying that robotics has a direct impact on achieving operational excellence and resilience at 60%.
“Smart robotic systems produce data to demonstrate that every task aligns with regulatory requirements,” Haines explains. “When reconfiguring or optimising
Manufacturers could benefit from ongoing support, in order to meet quality and output goals – and more besides
a production line, it is even possible to check ahead of time with a digital twin without time-consuming revalidation.”
But for this supplier, the concept of ‘agility’ also extends throughout the entire lifecycle of a facility. It underlines the role of ongoing consultancy support, not only in helping manufacturers to meet quality and output goals, but also in avoiding unplanned outages. It recommends a service plan agreed with a partner demonstrating expertise in advanced robotics and automation.
“Contracts like this operate throughout the whole life of an asset to consolidate the multiple complex elements of predictive maintenance, energy management, 24/7 monitoring, and power continuity,” says Haines.
DODGING DOWNTIME
The point about power is not an arbitrary one.
“Continuous power is critical to success in pharmaceutical manufacturing, as any disruption or loss of power, no matter how small, has the potential to disrupt validated processes,” he explains.
“Any unplanned downtime will affect a manufacturer’s data integrity, resulting in lost batches and lost earnings.”
Returning to the theme of ‘agility’, Haines argues that the key is to deploy technology with its full lifecycle in mind, and to draw on service support from a dedicated partner.
“This will add value long after deployment to create a reliable facility that uses every resource effectively,” he claims.
The company concludes by saying that pharmaceutical manufacturers looking to mitigate risk, adhere to strict regulations, reduce downtime, and maintain operational excellence should adopt a longterm mindset. A single-source supplier, it underlines, can achieve this through a tailored service plan that combines
data from 24/7 monitoring with technical consultancy to increase software reliability and improve performance by predicting failures before
they happen.
The result brings together power and process, says Haines, and combines reassurance in terms of
operations and standards with the prospect of continuously improving sustainability, too.
T 0330 587 8030
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ifm – close to you
Feature: Pharmaceuticals & healthcare
Serialised pharma coding could soon hit, claims Domino
Four years after it was originally launched to offer high-resolution variable data printing, the K600G piezo drop-on-demand digital system has seen a number of improvements, says supplier Domino Printing Sciences, to further facilitate applications in individual pharmaceutical dose serialisation.
Strategic manager for digital coding at Domino Ian Chapman believes that individual dose serialisation is the next obvious step in pharmaceutical regulation.
“It is not a matter of if manufacturers will have to comply; the key question is when,” he says. “We developed the K600G with these future requirements in mind. We want to make it as seamless as possible for manufacturers to explore more advanced serialisation.”
Domino claims to be the first major global coding and marking supplier to offer systems tailored for this particular application.
A major South African pharmaceutical manufacturer and long-term Domino customer was one of the first companies to trial the K600G. According to the supplier, the manufacturer praised Domino’s willingness to do “everything possible” to meet its specific needs, within its required timescale.
During the customer trials, operator ergonomics, usability, and physical machine size were
Regulation on serialisation?
The K600G has been improved to suit the needs of pharmaceutical operations, says Domino, and any future demand for serialised coding
all highlighted as being of key importance to customers when selecting a variable print system, says Domino. The company says it has carried out re-engineering on the basis of this feedback.
For example, the improved K600G is fully integrated, with all controls incorporated into the frame of the machine, resulting in an overall footprint reduction of 35%. Domino argues that the smaller systems are easier to integrate into existing pharmaceutical packaging lines, including space-constrained clean room environments, without necessitating significant line changes or upgrades.
The new systems also feature a single touchscreen interface incorporating all previous control panels, making it easier for operators to manage production runs from a single location.
According to Domino, the K600G benefits from the automated cleaning and maintenance features within Domino’s established K600i, further reducing the risk of downtime. Automatic printhead cleaning and capping from the i-Tech CleanCap system removes the need for regular manual cleaning and maintenance
requirements. At the same time, a technology called i-Tech ActiFlow is said to keep the ink in the system constantly moving to prevent the formation of air bubbles that can otherwise impact nozzle performance.
“We are committed to using our advanced variable data printing expertise to help develop solutions that solve our customers’ needs, but to do this effectively, we also need to work with our customers, to listen, and to act,” says Tony McNulty, chief product officer at Domino. “With the K600G, we developed a solution that would help pharmaceutical manufacturers to futureproof their lines against future regulatory changes; with our customers’ support, we have made the solution more accessible than ever.”
The K600G was developed for high-speed coding on pharmaceutical packaging, such as labels, medical-grade substrates including Tyvek, and blister foils. Options are available to suit different installation types, including off-line, near-line, top-of-line, and sealed-blistercoding variants.
T 01954 782551
W www.domino-uk.com
Feature: Pharmaceuticals & healthcare
Lineside is never simply a sideline
Omron argues that the timely replenishment of machines can often be entrusted to AMRs
Despite traditionally higher margins than some other manufacturing sectors, the pharmaceuticals and healthcare sector is, according to automation specialist Omron, experiencing pressure to contain costs while also sharing many of the same staff recruitment and retention issues facing other industries.
The increasing burden of ingredient, packaging and other supply chain costs means that efficiency is more important than ever, says Omron marketing manager for UK and Ireland Stuart Coulton. He believes that lineside replenishment is a particular pain point.
“A critical bottleneck has emerged in the physical transportation of clean, empty vials and secondary packaging materials to production lines, primarily due to a lack of available workforce to push carts,” he says.
As Coulton points out, any
of pharmaceutical facilities,” he explains.
Coulton cites the example of one biotech company which needs to move 700 boxes of vaccine vials, each weighing 70kg, from the warehouse to the production area every day, while also maintaining a 100% clean environment.
Autonomous mobile robots (AMRs), says Omron, address the various interconnected issues affecting replenishment.
These intelligent vehicles have been designed to increase throughput, reduce machine downtime, eliminate errors, and improve material traceability, it points out. They avoid the challenges associated with workforce shortages and with the need for high levels of hygiene.
accumulation in delays to replenishment may not only drive down profits but also contribute to medicine shortages.
“This challenge is even more marked in environments where forklifts and other mechanical handling equipment are not viable, due to the strict hygiene standards and spatial constraints typical
AMRs can not only be programmed to deliver materials precisely when and where they are needed, but are also capable of monitoring consumption rates and predicting when materials will run out.
“AMRs offer a totally flexible way to improve production efficiency in the pharmaceutical industry,” says Coulton, adding that they can operate in clean rooms, and are easy to scale, modify and adapt as required.
“AMRs also address one of the most common concerns associated with automating lineside replenishment tasks: worker safety.” Unlike traditional robots, he explains, AMRs are designed to operate in harmony with human workers.
T 01908 258258
W www.industrial.omron.co.uk
Mobile robots come into their own where there is less space
Fully-automated filling of liquid medicines and alternative healthcare products allows output increases
Full automation benefits liquids
Repeat accuracy is only one compelling reason among many to automate filling, says Karmelle
The use of fully-automatic filling for pharmaceutical and healthcare syrups, solutions and other liquids of differing consistencies has long been best practice in the industry, says filling equipment supplier Karmelle, and the arrival of AI and more intelligent systems provides an even stronger rationale for full automation.
With an unwavering focus on accuracy, reliability, and compliance, automatic filling machines are crucial to the packaging process, says the company, requiring precise dosing of vials, syringes and other containers with liquids, pastes or other semi-solids. As demand for pharmaceuticals continues to rise, driven by an ageing population and increasing healthcare needs, the significance of advanced filling technologies cannot be overstated.
These considerations hold true not only for mainstream medicines, but also for botanicals and other alternative healthcare products.
Managing director Peter Krawczuk underlines the critical importance of accuracy in the quality-sensitive
healthcare sector. “This is why Karmelle’s machines have been designed to deliver exceptional performance, capable of filling a broad range of liquid products with varying viscosity,” he says.
Equipment such as Karmelle’s flowmeter filling machines provides not only repeat accuracy but also the flexibility to allow output to be increased to meet fluctuations in demand, says Krawczuk.
Although the initial investment in automated filling can be substantial, the company points out, the long-term savings are significant. Reduced labour costs, minimised waste and decreased risk of product recalls all contribute to the overall return on investment.
Even more exciting change could be on its way, says Krawczuk. “Innovations like AI are poised to further enhance the capabilities and efficiency of automatic filling machines,” he predicts. “Additionally, as personalised medicine gains traction, filling machines may need to adapt to producing increased variations of smaller batches.”
T 01484 533356
W www.karmelle.com
Feature: Pharmaceuticals & healthcare
Processing options call on vacuum and mechanochemistry
Whether at benchtopscale or at different production-scale levels of output, process technologies for pharmaceuticals and other health-related products continue to evolve and to keep pace with tight international regulation in the sector.
For Fette Compacting, this has meant launching the entire range of its new P-Series tablet presses over the course of the year. As UK subsidiary EuroPharma explains, the range now consists of the F30p (launched in May this year), the F10p and the F20p.
Priorities for this redesigned equipment included ease of cleaning, says EuroPharma, with a dust-tight design taking in the HMI, electrical cabinet and tablet chute. A second priority, ease of operation, means that the HMI interface is intuitive to use. Adjustments are tool-free and easily-reproducible, it adds, and there has been a “simplification” of validation processes.
The range, which EuroPharma describes as “digital-ready”, can help to save energy thanks to the main torque drive and control system, and save space thanks to the compact design. As universal tablet presses, they are widely adapted to different powders, says EuroPharma. The integrated electrical cabinets are all rated to IP54 standard.
From lab-scale to bulk output
A vacuum system from Volkmann mounted inside an isolator, and able to provide conveying that is efficient and free from contamination
The path from lab to full production is a well-trodden one in pharmaceuticals, and this is the route that Friedheim International is mapping out for
the IMPA°CT REACTOR from Swiss engineering company WAB, which it now supplies in the UK.
The UK company describes the system as “an inductivelyheated agitator bead mill reactor designed for continuous mechanochemistry”, which allows reactants to be heated to 160°C. At the same time, it facilitates control and logging of important process parameters such as temperature and energy input.
“A remarkable feature of the reactor is its scalability, offering an accurate and logical transition from milligrams per hour to tonnes per hour on an industrial scale,” says Friedheim.
The company argues that recent advances in mechanochemical methodologies have highlighted a promising solvent-free strategy for the synthesis of paracetamol (acetaminophen), for example, using DYNO-MILL technology. This approach presents several advantages over traditional solvent-based processes, it adds, making it a more sustainable and efficient method for producing this widely-used pharmaceutical.
The latest WAB reactor builds on this proven technology, but with the added capability of being able
to regulate heat and energy. Volkmann, meanwhile, emphasises its expertise in supplying reliable, hygienic and efficient vacuum-based materials handling for use in different areas of pharma manufacturing. These systems can be used for pharmaceutical powder, granules, finished tablets or other bulk formats throughout the process.
The company maintains that demand from the sector is only going to increase, given the ability of vacuum conveyors to keep product uncontaminated and segregated. It makes the point that product and material flows have typically become highly automated on the primary, secondary and tertiary packaging side of a pharmaceuticals operation. This is often not the case on the processing side.
Innovations from Volkmann include the Multijector vacuum conveyor, with a level-controlled buffer hopper for product transfer. This and other vacuum conveyors can be used to supply mixers, tablet presses, storage such as silos, or downstream packaging lines.
W www.europharma.co.uk
W www.friedheim.co.uk
W volkmann.info
The F30p tablet press
Automating tasks across healthcare
Medical device production and the various packaging functions for pharmaceuticals are chasing automation
Naturally enough, some of the challenges facing pharma and healthcare manufacturers, such as staff buy-in to automation, are not specific to this sector.
But the fact that operators at the Takeda Pharmaceutical Company in Oranienburg, Germany, were hand-palletising weights of up to 5.8 tonnes per shift certainly helped to move opinion in favour of a robotic alternative.
Now the cases of tablets and capsules are lifted by a CR-15iA cobot from Fanuc, sourced by system integrator SKDK. “We sold the robots as new colleagues, not as new technology,” says Takeda
project manager Robert Grundlach.
For Fanuc’s Sebastian Steinbach, who supported the project on-site, the lack of any requirement for guarding or a cage made a big difference.
“Staff can go within touching distance of our collaborative robots,” he says. “This made the introduction of new
technology more readily acceptable.”
Nonetheless, many operations in the industry are constrained by factors that do not affect most other types of manufacturing – not least the costs associated with operating within cleanroom conditions.
When US custom machine builder and member of the
Close working with the new cobot
Rockwell Automation PartnerNetwork programme Automation NTH was approached by a medical device manufacturer, the challenge was how to transition from manual assembly to automated production.
US medical devices are subject to FDA design validation that includes verification of manufacturing controls throughout the process.
Vice-president for engineering at the automation company Jeff Buck explains some of the priorities in scaling up. “They asked us to determine a way to increase capacity and decrease costs,” he says. “Specifically, they wanted to maintain the
Automation NTH innovated to increase capacity while reducing costs
validated process – while lowering the overall cost of the finished product.”
Buck and his team determined that the production costs of the assembly process were driven by the extensive footprint of the system, and the fact that the assembly cleanroom was a “costly environment”.
“Scaling up production by increasing the manufacturing footprint would adversely impact product price,” he says.
FINE LINE CONTROLS
For a more cost-effective approach, Automation NTH turned to the MagneMover LITE intelligent conveyor system from Rockwell Automation. Instead of running at fixed speed and fixed pitch like conventional conveyors, it enables independent control of magnetically-propelled carriers on a track in a simpler, more compact footprint.
The system is designed to run light loads efficiently –and as a contactless drive system, says Rockwell, it performs well in a cleanroom environment.
Equally tied down to the requirements of the sector, Mespack’s MSPH series of vertical form-fill-seal machines is specifically designed for the pharmaceutical industry, complying as it does with precise regulations, such as GMP, GAMP5, FDA, and 21 CFR Part 11.
Mespack, which is represented in the UK by Acer Machinery Solutions, uses its Athena digital platform, designed to enhance
machine control and data analytics. The stainlesssteel system is fully servooperated, says the company, to give customers more
co-ordinated control of machine movements.
W acermachinerysolutions.co.uk
W fanuc.eu
W rockwellautomation.com
BLH Series
Series
Series
CVK Series
BLE2 Series KIIS Series DGII-Serie
Who What Where
Who’s done what and gone where...
Phoenix Contact
Andy Mills has stepped into the role of managing director at Phoenix Contact, replacing Colin Green, who has retired after 16 years at the company. Mills, who was formerly sales and marketing manager for industrial components and electronics, joined the business in 2005. Meanwhile, at the German parent company, Frank Stührenberg (below, right) and Dirk Görlitzer have been sharing the position of chief executive officer ahead of Stührenberg’s retirement from the role at the end of this year.
Ulma Packaging
Lee Driscoll is now UK sales manager for traysealers at Ulma Packaging, with responsibility for the UK and Ireland. He has over 20 years’ experience of selling equipment, and will focus on generating new customer leads and sector opportunities, working closely with regional sales teams to drive growth.
GEA
GEA has appointed Warren McCready as its country manager for Ireland and Northern Ireland. After an early career devoted to the FMCG sector, he moved on to sales of full production lines for leading equipment manufacturers. He brings breadth and depth of experience to his new role, says GEA.
Eriez
Todd Loudin has taken up the position of vice president of global sales at Eriez, boasting over three decades of experience in international business and sales management and, says the company, a proven track record of success. He most recently held a senior executive position at Valmet, a global leader in flow control.
Macsa id UK
Ryan Sears is now regional sales manager for the south at Macsa id UK, the coding and marking systems supplier. A Business Studies graduate, he spent four years at Four Digital Solutions. “The laser coding industry in particular is growing rapidly,” he says. “I am thrilled to be part of Macsa id UK’s journey.”
Optima group
Holmach
Lewis Peasgood has been welcomed back to Holmach as the new commercial director, having previously held the post of sales director at the company from 2018 to 2023, before briefly being enticed away elsewhere. He previously worked in sales and distribution at Linx Printing Technologies, where he proved a catalyst to expansion.
Ishida Europe
Ishida Europe has promoted longstanding employee Guy Dix to the position of technical director. From March 2022 he was engineering general manager, having first joined the company in 2005. He succeeds Seisaku Iwasa, who is returning to Japan to take up the role of production executive officer.
Germany’s Optima group says it has completed the “generational change” in its management, which is now led by: Stefan König (chief executive – centre, left), Hans Bühler (managing partner –centre, right), Marco Beyl (chief financial officer – far right) and Johannes-Thomas Grobe (chief executive, pharmaceuticals – far left). Beyl and Grobe joined the board after a structured one-year handover process with their predecessors. The group has around 3,150 employees in over 20 locations internationally.
23 – 25 SEPTEMBER
PPMA Total Show 2025 NEC, Birmingham www.ppmashow.co.uk
14 – 16 JANUARY
Gulf Print & Pack Riyadh, Saudi Arabia www.gulfprintpack.com/riyadh
22 – 23 JANUARY
Pharmapack Europe
Paris Expo, France www.pharmapackeurope.com/ en/home.html
Unit 4 Anglo Office Park, Lincoln Road, High Wycombe, Bucks, HP12 3RH Telephone: 01494 512228 Email: mail.uk@volkmann.info Website: https://uk.volkmann.info/
Volkmann UK Ltd Unit 4 Anglo Office Park, Lincoln Road, High Wycombe, Bucks, HP12 3RH Telephone: 01494 512228 Email: mail.uk@volkmann.info Website: https://uk.volkmann.info/
Oaks Industrial Est, Festive Drive, Loughborough, LE11 5XN T: 01509 857010 E: i nfo-uk@piab.com www.piab.com
Volkmann UK Ltd Unit 4 Anglo Office Park, Lincoln Road, High Wycombe, Bucks, HP12 3RH Telephone: 01494 512228 Email: mail.uk@volkmann.info Website: https://uk.volkmann.info/
T: 01484 715111 E: info@yps.co.uk W: www.yps.co.uk Prince of Wales Works, Armytage Road, Brighouse, West Yorkshire HD6 1QF
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