PACKAGING MACHINERY

Automated Production
Today, automated production is essential. Neither
volume nor product consistency can be achieved in any
other way.

Increasing production in a cost-effective manner is a

difficult and complex due to:
§  The time frame in which the product must be produced
§  Production volume
§  Quality standards
§  Equipment technology
§  Space constraint
§  Installation requirement
Automated Production
Increasing Production
Four options to increase production are:
§  Buy new state-of-the-art equipment.
§  Do something with existing equipment.
§  Buy refurbished equipment.
§  Hire a contract packager.

Factors that will influence this choice are as follows:

§  Availability of in-plant equipment
§  Market demand for the product
The New Production Line
The Packaging Machine Industry
Packaging machinery manufacture is a highly specialized
business that does not produce large numbers of identical
machines.

Products and packages come in such an infinite variety of

materials and forms that even though a company may
specialize in a particular machine class.

In this respect, packaging machinery is a custom business.

The New Production Line
The Packaging Machine Industry
Given that a complete packaging line may consist of six
functional stations from six suppliers, connected by
conveyors and buffers made by another supplier.

It is not likely that a new line can be plugged in and work

instantly and perfectly. New lines have to be debugged
and brought up to operating speed.
The New Production Line
General Considerations
Broad decisions as to machine class need to be made
early and are usually obvious. For example:
§  Will it be a dedicated machine or will it need
interchangeable parts?
§  Are particular standards of cleanliness and sterility
necessary?
§  Are active chemicals needing special corrosion
protection procedures a factor?
§  Should the machine flow be from left to right or right
to left?
The New Production Line
General Considerations
§  When examining candidate machines, remember that
good packaging lines accomplish their objective with a
minimum of vibration and noise.

§  The transfer and flow of product and material through

the production process should be smooth, with the
minimum of directional changes.

§  Before calling on machine suppliers, make a thorough

and critical analysis of what exactly needs to be
accomplished.
The New Production Line
General Considerations
§  Be realistic in the range of tasks that your machine will
be required to perform, and resist the temptation to
compromise the main objective. The more dedicated a
machine is, the more efficient it will be.

§  Capital outlay for machines can be heavy.

§  Effective servicing and parts supply is a key vendor

issue.
Speed
Terminology
The lack of specific and consistent terminology often makes
discussions of productivity confusing. For the purpose of
this discussion, the following definitions will be used:
§  Packaging line: A group of integrated special-purpose
machines that combine product and package inputs and
produce a new product.
§  Stations: are referred to individual machines, where
each performing a different function.
§  Input: Specific product and package items required for
package assembly.
Speed
Terminology
§  Design speed: The theoretical capacity under perfect
running conditions.
§  Design cycle rate: The speed of the machine as
designed, running empty.
§  Capacity: The upper sustainable limit of quality
packages passing a point just before warehousing.
§  Run speed: The instantaneous operating rate at a point
in time.
Speed
Terminology
§  Output: A packaging line’s output (designated Y) is the
exact quantity of quality product passing a point just
before warehousing or shipping in a given time. A
machine’s or station’s output is the exact quantity of
quality product leaving that machine in a given time.

§  Efficiency: Efficiency is a ratio of output over input.

Also, efficiency is used to describe a station’s or a
packaging line’s actual operating time over the available
time
Speed

The speed hierarchy would be as follows:

1  Design speed
2  Capacity
3  Run speed
4  Output rate
Straight-Line and Rotary Systems
Packaging machines such as fillers, cappers, and labelers
can be designed in straight-line and rotary configurations.

§  Straight-line machines usually index a product into an

operational station and then hold it there until the
operation is completed.

§  Continuous-motion (rotary) machines do not index a

container into a station and stop, but instead feed the
container into a rotating turret, where the operational
heads work on the moving container.
Straight-Line and Rotary Systems
Irregular-motion straight-line fillers move containers under
the filling heads and then stop for the fill cycle. The
machine may have one fill head or several fill heads
ganged together.
Straight-Line and Rotary Systems
Rotary machines require a timing screw on the conveyor
feeding into the starwheel to separate the containers to
the correct pitch.
Changeovers
The simplest change is when only the product needs to be
replaced.

For those applications where several different products will

be run on the same line, ease of changeover becomes an
important consideration.

Generally, the faster a machine operates, the more

complex the changeover.

Where changeovers are frequent, ease of changeover,

rather than actual machine speed, may dictate machine
choice.
Changeovers
Ideally, changeovers should be possible to make critical or
time-consuming adjustments. Make a histogram (a detailed
bar chart showing where time has been spent to effect the
changeover).

Total changeover time can be grouped into four main

categories:
1  Preparation or organization: get parts, get tools, locate
mechanics/operators
2  Changeover: remove and remount change parts
3  Measurement: settings, calibrations, centering
4  Trial run: run-in, final adjustments
Machine Controls
The motions of machine components are achieved, timed,
and controlled by various methods. They may be
mechanically activated by levers, push rods, or gears.

Motions can be controlled and implemented by

microswitches, timers, or any electronic means.

A machine runs best when all components are at their

optimum settings. These settings should be determined
and quantified and not left to operator option.
Machine Controls
Microelectronics and microprocessors have provided the
packaging engineer with endless possibilities for
continuous monitoring of station variables such as fill
weight, throughput, production speed, and machine
settings.

Designing special-purpose machines to perform totally

new functions is an especially difficult task, one not to be
taken lightly.
Developing Custom Machinery
The design of a unique machine usually goes through the
following stages:
1.  Conceptual development (ideas for how each step will
be achieved)
2.  Construction of station models
3.  Creation of assembly and detail drawings for prototype
machine
4.  Construction of prototype machine
5.  Test run of prototype machine in production environment
6.  Modification and improvement of prototype machine
7.  Creation of assembly and detail drawings for production
machine
8.  Construction and commissioning of production line
Developing Custom Machinery

Depending on available expertise, some steps may be

shortened or circumvented. Design of special-purpose
machines is a high-risk activity and should be approached
with caution.
Upgrading Existing Equipment
Refurbishing existing in-house equipment, if it is possible
to do so, has definite benefits:
1  You are working with proven technology (for in-house
equipment).
2  There are no capital costs for upgrading existing
equipment.
3  Initial training and commissioning problems are
reduced.