8 top Packaging Lines for Engineers July 2013

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12/23/2014
8 top packaging lines for engineers | Packaging Digest
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packaging lines for engineers
8
top packaging lines for
engineers
By Jack Mans in Packaging Design (/packagingdesign) on
July 31, 2013
Since our startup 50 years ago, the packagingline story has been the heart and soul of
Packaging Digest. During the past 10 years
alone, we have done about 600 line stories. As I
went through every issue from the last decade, I
discovered how hard it was to select just a
handful-I liked them all.
http://www.packagingdigest.com/packagingdesign/8toppackaginglinesengineers
1/19
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So what I am presenting here are my choices of
some of the best packaging line stories of the
past 10 years. I am sure that any of you readers
who look at these past issues would select other
stories, but this is my feature so my choices.
I decided on several criteria for these selections.
The stories had to be about complete packaging
lines. Some of our stories focus on single
machines on a line, but this is supposed to be
about line stories, so I have not considered
those. Every story here is about a complete line
starting with bottle, carton or film delivery and
ending with case packing or palletizing.
In each story, I have selected one machine
supplier to illustrate the operation. If the
emphasis of the story is on a specific technology
(though it is still a complete line story), I have
identified that piece of equipment. Otherwise, I
have selected the filler because, in my opinion,
the filler is the most critical and distinguishing
machine on a line. If anyone would like to see a
list of all of the equipment suppliers on the line,
click on the web address at the end of the
particular item.
Anyway, here are the stories I have selected,
along with the features of the line that
prompted my decision.
Bottles fly on new aseptic line
An 81-head low-acid aseptic rotary filler at the
HP Hood plant in Sacramento, CA, runs 600
bottles/min on a highly automated and flexible
packaging line designed for fast, pushbutton
operation. The filler was manufactured by
Shibuya Kogyo Corp. (Shibuya Hoppmann Corp.
in the U.S.).
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The Shibuya filler was the first FDA-accepted
rotary filler for low-acid beverages when it was
validated in 2005, and the packaging line at the
Sacramento plant is one of the fastest and most
sophisticated low-acid aseptic lines in the
world.
Hood installed the first Shibuya aseptic low-acid
rotary filler in the dairy industry at its plant in
Winchester, VA, in 2004. When the machine was
installed in the Sacramento plant, there were
only three Shibuya aseptic machines in the U.S.,
and Hood had two of them.
The Shibuya system is equipped with a fully
automated CIP/SIP system that cleans and
sterilizes the product lines and enclosure before
each operating cycle. The system can maintain
an aseptic environment inside the aseptic
chambers for up to 156 consecutive hours.
During this time, access is provided through
glove boxes, and the entire system must be
resterilized if sterility is broken. Bottles are
sterilized by vaporized hydrogen peroxide
sprayed into them.
The Shibuya system actually incorporates three
operations-sterilizing/rinsing, filling and
capping. Bottles are transported through the
operation by clamps that grasp the bottle at the
neck. Neck gripping allows for the filler to
accommodate different sized bottles with
minimal changeover required.
All of the conveyors and equipment in the line,
except for the Shibuya filler, are monitored and
controlled from the HMI in the control room.
The entire Shibuya operation can be monitored
by a centrally located SCADA computer and is
operated through a touchscreen HMI. Hood
runs a number of different bottles on the
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aseptic line and each requires different
sterilizing conditions, depending on shape and
size. Torque settings are also different for
different bottles. Once these operating
parameters are set for a container, they can be
recalled automatically on the touchscreen.
To see the original story, click on
www.packagingdigest.com/HPHood. (/HPHood)
(/HPHood)
(Integrated systems help Blockbuster improve
video disc packaging for speedy order
fulfillment.)
New labeling, loading method is a smash hit at
Blockbuster
Blockbuster Video, McKinney, TX, redesigned
four packaging lines and added a fifth
automated line to its 850,000-sq-ft
packaging/distribution center to cut reject rates
and improve the data flow and processing of
rental products for timely delivery.
The project involved modifying some of the
existing packaging equipment and
incorporating new technology to save both time
and money. Blockbuster worked with Videojet
Technologies Inc. and DVD video-disc packaging
equipment manufacturer GIMA S.p.A., Bologna,
Italy, for assistance on this project.
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The four existing packaging lines and the new
automated fifth line are managed by Videojet's
Data Management System (DMS). The DMS is a
customized suite of seven separate software
applications developed specifically for
Blockbuster by Videojet's Integrated Solutions
Group. It provides a data control and reporting
system that handles a flow of information in
real time between Blockbuster's warehousemanagement system (WMS) and movie-rental
product-handling machines from GIMA on the
five lines. The interface links the host WMS
information into the packaging equipment and
manages the data for each production run,
feeding the information back to the host WMS.
Altogether, five GIMA DVD872 disc-packaging
machines, five GIMA 8A6 labeling machines,
five GIMA 8A5 vertical hoppers and five GIMA
8A7 tote packer/collators were installed.
The results produced an integrated packaging
line that delivers "perfect" order fulfillment and
process efficiencies, a reduction in product
damage and a reduction in rejection rates from
0.5 percent to less than 0.01 percent.
Operational efficiencies have improved by more
than 40 percent while downtime has dropped to
less than 5 percent.
www.packagingdigest.com/Blockbuster
(/Blockbuster).
A ‘suite' spot for flex packs
GSC Packaging's move into a new 100,000-sq-ft
facility with 16 separate side-by-side packaging
suites improves quality control and removes
much of the risk of product contamination.
Because it packages nutraceuticals and dietary
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supplements, the plant adheres to 21CFR111
guidelines that are a higher standard than for
food processing for all products.
Entered through a plastic curtain, each suite is
subdivided into primary and secondary
packaging operations and offers positive air
flow and state-of-the-art dust collection for the
largely powdery products.
The new facility also positions the contract
packager for continued growth in stick packs,
pouches and bags for powdered and other dry
products.
Within the suites, the plant boasts 15 packaging
production lines comprising seven horizontal
form/fill/seal (FFS) lines, three six-lane stick
pack vertical FFS packaging lines, as well as
various semi-automatic, large-format automatic,
secondary packaging, shrink wrapping, banding
and cartoning, kitting and point-of-purchase
display packaging. The newest FFS machine at
GSC is a Model ST560 stick-pack machine from
Viking Masek Global Packaging Technologies.
Using these systems, GSC Packaging packages
dry food-grade powders and particulates for
products, including nutritional and protein
supplements, drink mixes, dry cereals, hot
chocolate mix and cheese powders. In addition
to powdered products, it also packages
croutons, soup mixes and rice. These dry
foodstuffs are packaged into three primary
package formats, all of which are flexibles: stick
packs, stand-up pouches and bags that range in
size from a 2x2-inch sugar-packet size sachet to
a large-format, one-kilo bag 18 inches tall x 12
inches wide.
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www.packagingdigest.com/GSC (/GSC).
Filler gets a grip on accuracy
Founded in 1932, Xttrium Laboratories, Mt.
Prospect, IL, is one of the largest U.S. suppliers
of FDA-approved 2- and 4-percent chlorhexidine
gluconate (CHG) formulations. These are
antimicrobials for surgical scrubbing and health
care personnel hand washing.
Xttrium opened a new 106,000-sq-ft facility
earlier this year and installed two new
monobloc filler/cappers from Serac Inc.: (1) A
basic model RB machine that essentially is
dedicated to running a single bottle size and the
star of Serac's product line, and (2) its new
model FC machine on which Xttrium runs bottle
sizes ranging from 4 to 32 fl oz.
With its host of technological advances, Xttrium
sees the new FC machine as an excellent answer
for its requirements of sanitation, accuracy,
speed and easy maintenance.
Features of the FC machine include:
• All machine components are mounted above
the floor and are enclosed by large sliding doors
that provide total visibility and accessibility for
easy maintenance and operation.
• New universal transfer clamps hold the bottles
by the neck. The system can handle neck
diameter ranging from 25 to 45mm and 35 to
60mm and bottles of almost any height without
requiring a change of tooling.
• A new valve design uses magnets positioned
inside and outside of the fill-nozzle cylinder.
The inner magnet is attached to the fill valve
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and a vertical screw on the outside of the
housing moves the outer magnet up or down.
This "drags" the inside magnet with the attached
fill valve to the proper position.
• Serac's patented Dynaflow technology
achieves extreme accuracy, while optimizing
the filling time based on the product
specifications. The Dynaflow can be thought of
as a smart flow-meter that controls and adjusts
the flow of product based on how much weight
is filled into the container during a filling
period. The filling accuracy is not affected by
any variation of product temperature or
viscosity, and it allows direct connection from
the process piping to the filling valves. This
eliminates the need for a hold tank on the filler,
simplifying the cleaning process.
• In addition to handling the net weight
calculations, the computer-based control system
on the filler records processing and filling data
for every bottle run and provides statistical
production feedback.
The machine was designed with the operator
and maintenance personnel in mind. The
control cabinet is mounted on the machine
instead of the wall, which eliminates external
wiring and cable runs and provides easy
operator access.
www.packagingdigest.com/Xttrium (/Xttrium).
Cosmeceuticals company lifts filling
productivity
Hawknad Mfg. Industries Inc., Alexandria, VA,
tripled its filling productivity by installing a
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customized UniPuck adjustable-puck in-line
filling system from TurboFil Packaging
Machines.
The automated system, which uses UniPucks to
steady and fill bottles and jars of different
shapes and sizes, eliminates manual filling
regardless of bottle shape or size and tripled
production from 2,000 to 6,000 units/day.
Hawknad runs a variety of lotions and creams
ranging from complexion lightening creams to
acne lotions. Particularly challenging were 6-oz
Silique tottles used for high-viscosity lotions.
The tottles, which essentially are bottles that
stand on their caps, presented two challenges
when Hawknad looked to automate the filling
operation: The tottles needed to be steadied by a
puck system, and they are filled from the
bottom-up.
Hawknad decided to go with the UniPuck
adjustable in-line filling system because the
easily adjusted pucks allowed quick
changeovers between different types of
containers, and the in-line filling heads could be
used for top or bottom filling. TurboFil
Packaging Machines worked with partners to
create a small, automated filling system that not
only met Hawknad's requirements, but would
work as one unit.
Hawknad's filler is custom-configured with
four, piston fill heads with positive shutoff
nozzles that achieve high precision (+/-0.2
percent) and nonsplash and nondrip operation.
The system fills bottles from the bottom-up with
high-viscosity creams and lotions at a speed 50
filling cycles/min.
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In operation, containers are manually placed in
the UniPucks, which then carry the pucks to the
filler. When five bottles are in place, a sensor
signals the machine to lift the first four bottles,
fill them and lower them gradually.
www.packagingdigest.com/Hawknad
(/Hawknad).
Zippy new carton is revolutionary
U.S. Sugar Corp. is the first company in the
world to market its product in a revolutionary
new cartoning concept called Zipbox that
integrates a poly-coated paperboard carton with
an attached flexible film header containing a
zipper. Zipbox is a joint venture between
T.H.E.M. and the Zip-Pak division of Illinois Tool
Works Inc. (ITW).
Among the many features of the new Zipbox is a
DoubleZip press-to-close zipper on top that
allows for easy opening and closing, and an
airtight seal configuration on the package
bottom that eliminates the need for an
additional liner to maintain product freshness.
Zipbox cartons are produced on a Model MP2
Assembly Machine from Zip-Pak Systems. This
is the same machine that is used to apply
zippers to flexible bags. In this operation, folded
cartons are fed into the machine from a
magazine, while zipper and film are on rolls on
the front of the machine.
The flat film is pulled into the machine and is
folded to form a "C" shape with the trough of the
"C" facing upward. The zipper is inserted down
into the trough in the film, which is heat sealed
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above it. The film/zipper is then folded over the
edges of the carton and is heat sealed to the
cartons.
Carton erecting, filling and sealing is done on a
system designed and built by Yeaman Machine
Technologies. In this process, the Zipbox cartons
are placed in a magazine with the zipper section
facing upward. The cartons are filled through
the bottom, so an arm rotates the cartons 180
deg, so that the zipper tops are on the bottom
and the open carton bottoms face upward.
www.packagingdigest.com/USSugar (/USSugar).
Putting the Plus in Sanofi's new blister pack
A new custom-made packaging machine was a
critical element when giant French drug maker
Sanofi introduced an updated version of its
Maalox heartburn relief product in a new
blister pack design. Called Maalox Plus, the
product, which was introduced in Italy, adds
simethicone to standard Maalox. A key design
element of the new machine was flexibility. It
must be able to fulfill numerous customer
requirements and create a variety of pack
styles.
The package for Maalox Plus is a new blister
pack design that combines a traditional
thermoformed/foil-sealed blister and a patient
information leaflet (PIL) together in a compact
carton that has an engaging opening system.
The user-friendly package contains two
thermoformed and foil-sealed blisters-each
holding six tablets-as well as an information
booklet, all permanently contained in the
carton. This keeps vital product information
connected to the package throughout its
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use. Consumers open the double-blister pack by
pulling out a blister on one side, which
automatically pushes the second blister out the
opposite side. It's somewhat like a teeter-totter,
except it moves side-by-side instead of up-anddown.
Key to the package is the slider system, which is
protected by numerous international patents.
The slider was also one of the most challenging
elements of the packaging machine design.
To automate production of the slider blister
pack in adequate volumes, slider-pack designer
Burgopak Healthcare & Technology partnered
with Bosch Packaging Systems, which was
chosen for its experience in feeding, product
handling and film handling at high speed. Built
by Bosch in Switzerland, the custom-made
Burgopak system assembles the separate
components-blister, booklet and carton-to
create a fully functional Burgopak slider pack.
www.packagingdigest.com/MaaloxPlus
(/MaaloxPlus).
Lean efficiency pays dividends
From simple beginnings in a 50,000-sq-ft
facility, contract packager Aerofil Technology
Inc., Sullivan, MO, has grown into a 400,000-sqft facility with 16 production lines. Key to this
growth has been a commitment to a culture of
total employee empowerment that drives
continuous improvement every day.
ATI adopted the philosophies and practices of
the Toyota Production System (TPS), and it had
an immediate and dramatic impact on the
entire workforce and culture. At the core of the
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learning, ATI focused on what it considers its
most valuable resource-its employees. It
engaged every single employee throughout the
entire enterprise, driving continuous
improvement on a daily basis.
In the spring of 2009, ATI began looking for the
latest high-tech/high-speed liquid bottling line
available in the marketplace. In designing the
high-speed line, ATI first established the
operational requirements for each piece of
equipment on the new line and then used
another Lean tool known as 3P (Production,
Preparation, Process) to optimize the line
layout. This provided a good idea of how the
equipment would fit in the room, and how
accessible it would be for the operators.
The result is an efficient high-speed packaging
line that is operated by only three people. The
new line, which started in October 2012, runs 15
different bottles with seven different closures,
including trigger sprayers.
A major change that was instituted for the new
line was that processing and packaging are in
the same room, though they are in separately
defined areas. The company had always located
processing and packaging in separate rooms,
but this new arrangement allows close
interaction and effective communication
between blending operators and line operators.
ATI installed a Pneumatic Scale Angelus (PSA)
monobloc filler/capper that includes a 30-head
mass flow filler and a 12-head capper. The filler
incorporates Coriolis technology that achieves
+/-1g fill accuracy. To meet ATI's explosionproof requirement, the monobloc system is
rated as intrinsically safe.
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www.packagingdigest.com/Aerofil (/Aerofil).
Shibuya Hoppmann Corp., 800-368-3582
www.shibuyahoppmann.com
(http://www.shibuyahoppmann.com)
GIMA S.p.A., 39 051 6169711
www.gima.com (http://www.gima.com)
(http://www.gima.com)
Videojet Technologies Inc., 630-860-7300
www.videojet.com (http://www.videojet.com)
Viking Masek Global Packaging Technologies,
920-564-5051; www.vikingmasek.com
(http://www.vikingmasek.com)
Serac Inc., 630-510-9343
www.serac-group.com (http://www.seracgroup.com)
TurboFil Packaging Machines LLC, 914-239-3878
www.turbofil.com
(http://www.turbofil.com)
T.H.E.M., 800-322-8436
www.them.net (http://www.them.net);
www.zipbox.net (http://www.zipbox.net)
Yeaman Machine Technologies, 847-758-0500
www.yeamanmachine.net
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(http://www.yeamanmachine.net)
Zip-Pak, Div. of Illinois Tool Works Inc.,
773-715-3121
www.zippak.com (http://www.zippak.com)
(http://www.zippak.com)
Zip-Pak Systems, 770-921-1777
www.zippak.com (http://www.zippak.com)
Bosch Packaging Systems, 919-413-3307
www.boschpackaging.com
(http://www.boschpackaging.com)
(http://www.boschpackaging.com)
Burgopak Healthcare & Technology, +44 207 089
1950; www.burgopakhealthcare.com
(http://www.burgopakhealthcare.com)
Pneumatic Scale Corp., 330-923-049
www.barry-wehmillerco.com
(http://www.barry-wehmillerco.com)
.
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Post
August 27th, 2013
All very interesting applications. 50% were bottling. I
hope that we could see some application that has to
deal with perishable food in some form; with its
associated challenges.
Reply
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8 top Packaging Lines for Engineers July 2013

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