review of the year
Transcription
review of the year
REVIEW OF THE YEAR A PROMOTIONAL SUPPLEMENT 2015 Changeover is reduced and film wastage is cut The site uses Celox cartoners MBP R-series baggers employ a completely revised film feed arrangement to provide faster changeovers while reducing any film wastage A range of bagging machines that provide faster and more accurate changeover through a radically new film handling system was launched by PFM Packaging Machinery at the PPMA 2015 Show. “The new MBP R-series machines represent a milestone in bagger operation,” says PFM sales and operations director Chris Bolton. “By automating film reel set-up, one of the most difficult and time-consuming tasks for operators has been eliminated. “It cuts changeover time substantially and virtually eliminates film often wasted as operators get film edges into alignment, particularly important for stand-up four-side-seal bags which are becoming increasingly popular,” he says. The film mounting and unwind mechanism is now mounted on the side of the machine rather than, traditionally, at the rear to give the operator a clear view and easy control over the film changeover process. However the key to the system is a turner bar that now directs film to the forming tube. The angle of the bar is adjustable via motors to provide lateral movement, and hence film centring, with the exact position held in the memory and monitored during production. “This means that rather than attempt to centre film largely by hand on a trial-anderror basis, the entire process is automatic and readily monitored from the front of the machine,” explains PFM’s Chris Bolton. Exhibits from PFM’s established range of machinery included the Scirocco high speed flow wrapper, Pearl entry level flow wrapper and the XC1 combination bagging/ weighing machine. There was also the latest version of the multi-format Vetta bagging machine on show at the NEC. T 0113 239 3401 W www.pfmuk.com Cartoning is collaborative for Weetabix Kliklok has worked closely with the Weetabix Food Company over recent years and has installed a number of automatic cartoning lines at its Kettering site to pack Alpen cereal bars and Weetabix biscuits. Due to layout changes in one of the packing lines at the Kettering site, Kliklok is now working on another new project to automatically accept wraps of biscuits arriving ‘on edge’ from a buffer storage unit and rotating them through 90 degrees, prior to being cartoned. To achieve this, Kliklok is designing two modified versions of its rotary transfer system (RTS). This is a continuous motion system that uses a series of turret arms which rotate in a cam track, the arms then lower and close a ‘pocket’ around the product to provide a gentle 90 degree transfer at speeds of up to 220 products per minute. The two new RTS units are scheduled for installation over the coming months. For Alpen bars, Weetabix chose a pair of Kliklok’s ECT500 top load carton/glue erectors, which were modified to run a 5-pack and 10-pack, while another success was a joint project with CKF Systems, providing two automated lines for wrapped packs of Weetabix biscuits. Each line included Kliklok’s Celox cartoner, running at speeds up to 200 cartons per minute, and incorporating laser coders, a low level carton hopper, plus 2D size change capability. T 01275 836131 W www.kliklok-int.com 2 MACHINERY UPDATE PROMOTIONAL SUPPLEMENT Review of the Year 2015 Success of the show helped 2015 become a great year for many Last year saw PPMA members take full advantage of the manufacturing recovery T he success of the PPMA Show last October is reflected in the pages of this Review of the Year, with several items covered first launched at the exhibition. For instance, a range of bagging machines that provide faster and more accurate changeover through a radically new film handling system was launched at the NEC-show by PFM Packaging Machinery. Also, Paramount Packaging showed two variations of the latest low maintenance, easy to use and energy efficient Alpha VII horizontal flow wrapping machine from Fuji Machinery Company, while Karmelle demonstrated a range of its larger equipment in filling, capping and labelling. The economic recovery has encouraged engineering innovation Production line efficiencies were the focus of Advanced Dynamics’ stand as it showcased its range of labelling and feeding equipment, while Interactive Coding Equipment launched two new features on its advanced Vulcan print and apply labeller. At the end of last year, Redpack launched a new IP-65-rated bottom seal flow wrapping machine designed to provide hygienic operation for users, and in the previous issue, we included a piece on 3D printing taking hold in print and apply labelling. Constraint free design is a benefit of 3D printing, said Denis Brett of Industrial Labelling Systems. Early last year, Motion Control Products introduced To-lo-matic’s IMA integrated servo motor actuators, described as the company’s most powerful integrated motor rod actuator. In the summer, we reported on French carton packaging company Emballage Technologies continuing to develop internationally by setting up a subsidiary in the UK under the name Etpack Sprinter UK, while in the pharmaceuticals feature in the Nov/Dec issue, Weber Packaging Solutions outlined the UDI (unique device identifiers) implementation steps to help medical device manufacturers comply with legislation. The economic recovery loosened end-users wallets and several installations were written about last year. Krones UK, for example, supplied a combination labeller from Kosme to Angus Dundee when the distiller brought the bottling operation of its scotch whiskies in-house. It is capable of applying both cold glue and self-adhesive labels. At the same time, drive systems were toughing it out in a hostile shellfish environment which was down to a special surface treatment introduced by Nord Drivesystems onto aluminium geared motors. Further food industry installations were at Weetabix involving a number of automatic cartoning lines from Kliklok at its Kettering plant and also a ready meals producer where a dual flash labelling system from Printsafe was handling over 30 ready meal lines. n Print and apply in multi orientations I nteractive Coding Equipment (ICE) launched two new features for its advanced Vulcan print and apply labeller at the PPMA Show, which enable the machine to apply labels to the front of a moving pack, or across adjacent panels of a case or shrink wrapped unit to allow information to be seen in various orientations. The new application features further extend the capabilities of the Vulcan. The Corner Wrap system applies the label to the trailing corner of the pack, using the Direct Apply printing method which is unique to the Vulcan. The system incorporates a simple, secondary pneumatic roller wipe to ensure full adhesion of the label around the corner and side of the product. For front of pack applications, the system uses a robust, pneumaticallycontrolled arm applicator. Both systems incorporate integrated pack detection and applicator home/ extended sensor functionality to ensure accurate label placement every time. ICE says throughput speeds are faster than typical front of pack and corner wrap machines. The new models retain the many unique technological benefits of the Vulcan, including 80% fewer wear parts for reduced maintenance requirements, electronic label supply that automatically adjusts and maintains tension, and clutchless thermal transfer ribbon drive. A compact design and small footprint means the machine can fit easily into existing packing lines. ICE also exhibited its recently launched Scorpion Thermal Inkjet Printer. The Scorpion has a unique printhead design which incorporates a novel Cartridge Protection System. This innovation reduces the uncapped time of the cartridge, allowing the use of inks suitable for non-porous substrates without loss of reliability or print quality. Also on display were other models from the ICE portfolio, demonstrating the company’s ability to tailor a coding solution to the requirements of individual customers. These include the marketleading Zodiac thermal transfer printer, Viper thermal inkjet printer and Torus large character marking printer. T 0115 964 0144 W www.interactivecoding.co.uk Visitors were invited to pre-register for a personalised gift, printed at the show MACHINERY UPDATE PROMOTIONAL SUPPLEMENT 3 Flexible labeller handles all types with precision A ngus Dundee is a family-owned company, with over 60 years’ experience of distilling, bottling and exporting its fine Scotch Whisky products and other spirits around the world. Their two distilleries, Tomintoul situated in the Speyside Glenlivet region and Glencadam, which is located in the Eastern Highlands of Scotland both produce high quality single malts. In 2011 the company decided to move into bottling its own products rather than use a contract packer and the old William Lawson site on the outskirts of Glasgow was identified as suitable and subsequently purchased. Having been empty for over ten years, a lot of work had to be done restoring the fabric of the buildings so creating new warehousing for casks, a new bottling hall, offices, tanker loading and disgorging, storage tanks, filtration, roads and car parking. The main board also appointed Martin Meldrum as general manager, operations in 2012 to oversee the huge investment and get the operation up to the quality standards required. “When I arrived at Angus Dundee there was one line in operation, which had to be re-sited to allow for our new 200 bpm line,” explains Meldrum. “I have had a number of years’ experience with Krones UK and Kosme so I had no hesitation in choosing their equipment for the new line,” he continues. “We have received excellent back up and support from an after sales and service perspective and the machine build quality has again been of the highest standard. “When the new Kosme machine arrived it was essentially plug and play,” he says. “I wanted a combination labeller capable of applying both cold glue and self-adhesive labels and the Kosme 1200-20-4 fitted the bill completely.” Combo unit meets needs The goal is to provide high quality products to customers when they want them The Kosme labeller is a type Combicol 1200-20-4 which has a 1200mm PCD table with 20 stepper motor driven bottle platforms on a 188.5mm pitch spacing which therefore provides the ultimate flexibility in terms of future bottle sizes and dresses to be handled. There are four stations fitted to the labeller with two being wet glue units and the other two applying self-adhesive labels with automatic splicing. Change parts have been Our success is based on tailoring product specs to meet exacting customer needs supplied to handle a total of nineteen different bottle formats ranging from 35cl up to 1 litre in flasks in addition to standard tall round bottles. The labeller is capable of running with optimum efficiency at a speed of 240 bottles per minute and is very much the heart of the new line at Angus Dundee. At the plant, there is a laser coding unit that is used for sequential numbering of some of the older malt whisky brands. One other feature is a full camera inspection and rejection system, which not only detects the presence of the label but also the labelling accuracy to programmable quality acceptance standards. T 01942 845000 W www.krones.com 4 MACHINERY UPDATE PROMOTIONAL SUPPLEMENT Review of the Year 2015 Drive systems tough it out in hostile shellfish environment “This new Nord solution means we no longer worry about drives all the time,” says Bram de Visser, technical service at the Dutch premium shellfish supplier A special surface treatment introduced by Nord Drivesystems has allowed aluminium geared motors at shellfish product supplier Krijn Verwijs to survive the hostile working environment. Before swapping to the new system, frequent drive replacements used to be the order of the day but, in contrast to standard cast Treated motor on left, untreated above iron geared motors, the nsd tupH surface treated motors from Nord suffer almost no corrosion in the plant. Krijn Verwijs is one of Europe’s foremost suppliers of shellfish products, blue mussels in particular. Fresh catches arriving at the factory are dumped into large basins with a constant flow of clean salt water, which serves to keep the product healthy while sand is thoroughly rinsed off. Given the close presence of these containers and the fact that live mussels are then conveyed wet as they come, all processing lines throughout the factory are inevitably exposed to a humid, salty atmosphere. This aggressive environment brings swift corrosion for all sorts of unprotected metal parts across process automation equipment. In the case of conventional cast iron geared motors, rusty spots first appear on brand new systems in a matter of weeks, and the end of life draws near for these units after only a year or two. Even special coatings or varnishes merely help to moderately delay the onset of corrosion. Stainless steel drives are not an option since they proved not only very costly but impractical – due to requisite disruptive cool off periods before every hose down. However, Nord says its nsd tupH surface treatment is resilient, affordable and easy to clean and it enables aluminium geared motors – which can very comfortably be washed down – to achieve stainless steel grade resistance to corrosion. LONGER SURFACE LIVES Krijn Verwijs has begun to roll out nsd tupH systems to provide considerably longer service lives in the salty atmosphere throughout its site. Though such aluminium geared motors do come at a premium compared to the price of conventional cast iron units, both lab trials and extensive real-life testing in the factory in Yerseke, Holland indicate that nsd tupH systems will last for the better part of the typical 10-year lifetime of a conveyor line, or even outlast the line. Krijn Verwijs will therefore no longer have to purchase five to ten replacement drives for every unit, nor bother with the expense and effort of maintenance work. The nsd tupH treatment is no coating application, but rather a surface conversion that produces a base layer permanently bonded to the substrate. Based on an electrolytic process, this treatment renders aluminium cases similarly unsusceptible to corrosion as stainless steel. The scratch resistant surface also becomes more than six times as hard as untreated alloy, and a thousand times as hard as paint. Featuring a lightweight, compact, and self-draining design, nsd tupH systems for the food industry can be easily washed down. They are impervious to common chemical cleaning agents while neither rinsing them with acids or alkaline solutions nor applying highpressure cleaners will do any damage. In addition, nsd tupH surface treatments are universally available for all Nord aluminium products. T 01235 534404 W www.nord.com MACHINERY UPDATE PROMOTIONAL SUPPLEMENT 5 New flow wrapping variations A t the PPMA Show 2015 Paramount Packaging – exclusive distributor of Fuji Machinery Company’s horizontal and vertical form, fill and seal equipment in the UK and Ireland for the food, pharmaceutical and medical device markets – exhibited two variations of the latest low maintenance, easy to use and energy efficient Alpha VII horizontal flow wrapping machine. An advanced box motion model offering airtight sealing for high speed gas flushing or modified atmosphere packaging (MAP) applications and a back-seal flow wrapper with inverted film feed for handling irregular shaped, fragile or sticky products such as fish, sausages or IV bags was displayed. Focke end of line packaging solutions were also highlighted on the stand. With advanced heat pipe end seal technology, faster temperature control and high pressure sealers, Fuji’s Alpha VII box motion horizontal flow-wrapper offers reduced energy usage and hermetic sealing making it ideal for high speed gas flushing or MAP applications where extended shelf life is a key requirement. Due to the additional dwell time, it can seal thicker wrapping materials so is better suited to handling taller and heavier products. The FW3710B model displayed at the show is also capable of producing on trend ‘stand up’ block bottom gable top packs which are becoming increasingly popular for packaging of gourmet sandwiches, for example. Other units in the box motion series are FW-3400B, FW3410B, FW3700B and FW-3710BSB. Fuji’s box motion and back Paramount demonstrated several systems at the show seal flow wrappers are capable of operating at speeds up to 250 packs a minute, with a cut off length of 430mm. Depending on the model, they can handle products measuring between 140mm and 200mm (width) and up to 100mm (height). T 01252 815252 W www.paramount-packaging. co.uk Stand focus was on production line efficiencies P roduction line efficiencies were the focus of Advanced Dynamics when it showcased its range of labelling and feeding equipment at PPMA 2015. The company recognises the need for manufacturers to keep lines running for longer by ensuring that a continuous supply of different products are fed automatically, thereby reducing downtime and saving on manual labour. It therefore demonstrated that a fully automatic size change can be done in seconds on a front and back labeller that will accommodate the majority of bottle shapes and sizes. A zero downtime version which allows live label changeover is also available. It also showcased an ELF20 desk top labeller complete with auto height set so that visitors considering their first foray into automation could see for themselves how by simply placing a different sized box or carton underneath the applicator, and pressing go, the unit automatically adapts to the change, freeing factory staff to concentrate on more productive tasks. In addition, the company exhibited a range of Pack Leader’s other labelling equipment from the compact ELF-50 desk-top labeller to in-line wraparound and top and base labelling machines which can be stand alone or integrated into a line for a variety of container sizes, cartons and bottle shapes. In addition, Advanced Dynamics demonstrated the Labellers from Pack Leader were demonstrated by Advanced Dynamics latest in feeding technology – Köra Packmat’s AF300 friction feeder which is perfect for the separation of flat products between 60gsm to 30mm and is also ideal as a paper feeder. T 01274 731222 W www.advanceddynamics. co.uk 6 MACHINERY UPDATE PROMOTIONAL SUPPLEMENT UDI Implementation Steps for Medical Device Manufacturers Review of the Year 2015 Identify the FDA requirements applicable to your device Check existing quality systems against FDA requirements Select label printing and device marking systems Design and procurement of labelling stock 1. W ith the FDA’s ruling, requiring UDIs (Unique Device Identifiers) to be assigned to medical devices and their related packaging now in force, general manager of Weber Packaging Solutions Patrick Hughes says manufacturers need to be certain that they have considered how this legislation affects their specific products, packaging and quality management systems. The UDI code is a unique numeric or alphanumeric code in two parts: a device identifier (DI), which is specific to a device model or type, and a production identifier (PI), which includes the current production information for that specific device, such as the production lot or batch number, the serial number and/or the date of expiry. The UDI code allows the device to be identified and traced through distribution and use by its label and marking, all of which can be cross-referenced with the GUDID (Global Unique Device Identifier Database). DO I NEED A UDI? “The first and most obvious question to be asked is: Does my product or device actually require a UDI, and if so, when should this be in place?” says Hughes. The requirements for device labels and device packaging to incorporate a UDI are being phased in over a number of years based on the risk factor of the device. For example, Class III devices, such as implantable pacemakers, must comply with the new rule within a year, Implants considered lifesustaining, or life-supporting devices must comply with the UDI rule within two years. Class II devices, medium risk products like infusion pumps, must comply within three years and low risk Class 1 products such as hand-held surgical instruments must comply within five years. Develop a quality plan for UDI requirements 2. 5. 6. Design artwork for labels and direct marking Establish barcode quality verification programme 9. 10. Substantiate implementation readiness as per the quality plan 13. Enter UDI data into the Global Unique Device Identification 14. Database 3. Select the barcode numbering system for device and packaging 7. Update quality system documentation to reflect UDI implementation 11. Obtain membership of FDA accredited issuing agency 4. Choose barcode style to be used on device and packaging 8. Validate UDI application processes. Protocol, execution, report 12. Go Live Here, Weber has outlined the UDI implementation steps so that medical device manufacturers can comply Aiding UDI compliance With UDIs (Unique Device Identifiers) needing to be assigned to medical devices and their related packaging we look at some of the common issues to consider Having established that a UDI is required, it is essential that consideration is given to existing manufacturing, marking and labelling processes as there may be changes required in a number of areas to meet compliance regulations, continues Hughes. The UDI must be present on the label of a device or directly marked on the device itself and each UDI needs to be in both a plaintext version and in a form that uses automatic identification and data capture (AIDC) technology. MULTIPLE UNITS For products packed in multiple units, the UDI needs to be present on each individual device and on the outer carton. It is also important to consider which barcode or other AIDC technology is most appropriate, not only for any given device, but also Weber offers a consultative approach to find a solution for each stage of the device process the needs of the end user. For example, if the device has a long UDI number and a relatively small pack, manufacturers may need to consider using a 2-D Matrix style barcode to be able to fit all of the data on the label. Alternatively, for devices with a large label, and which will ultimately be used in local health centres or doctors surgeries, a conventional linear barcode may be more appropriate, as these sites may have limited bar code reader capability. Under the new legislation, manufacturers are free to choose the code type as long as there is appropriate technology that can be used to acquire the data in the field. Each manufacturer will MACHINERY UPDATE PROMOTIONAL SUPPLEMENT 7 potentially face a unique series of challenges when setting out to meet UDI requirements and we can assist by offering a consultative approach, covering systems, hardware and software, to help manufacturers define their UDI strategy, says Hughes. Looking beyond the immediate tasks of ensuring compliance with UDI, the company provides a holistic approach to labelling and marking, delivering the systems, software, ongoing maintenance, consumables and support necessary to maintain compliance, as the various regulatory stages are implemented. And, as the company has a global presence, it is able to support manufacturers undertaking UDI compliance in all major device markets. SUPPORT NETWORK “Combining this expertise and support network with the comprehensive array of printing and application technologies means that solutions for each stage of the manufacturing process, from the device production to pallet labelling, can be configured to meet the specific requirements of individual devices and manufacturers,” says Hughes. Available technologies include thermal inkjet systems, label printers, applicators and print & apply systems. In addition to the standard product and pallet label applicators, the portfolio also includes RFID solutions, providing manufacturers with a wide choice of labelling solutions to meet UDI requirements, irrespective of the device and its packaging. T 01875 611111 W www.weber.co.uk General manager Patrick Hughes from Weber Packaging Solutions 3D printing takes hold in print and apply labelling R obust , lightweight, flexible and rapid prototyping are all major benefits of introducing 3D printed components into the design and manufacture of industrial machinery and print and apply labelling is no exception,” says Denis Brett of Industrial Labelling Systems (ILS). Especially, he continues with the latest machines on offer from the company. “As time passes by we are seeing more and more parts on the standard machines being designed with 3D printed parts as opposed to more traditional manufactured methods,” he says. “Not only standard parts but now even complex designs are enabling components to be produced that couldn’t have been manufactured in any other way.” Constraint free design is another benefit of 3D printing. “Designers have suffered in the past when designing parts due to the weaknesses of “ This nylon blow vac non-contact pad with built in Venturi is used by ILS certain materials,” continues Brett. This could be weight, fragility or just a general difficulty to manufacture something so small and complex. “3D printing enables a much freer outlook to design and when manufactured you can be sure the component will be within specification,” he tells Machinery Update. Reduced development costs and speed to market on custom designs are other benefits of 3D printing. With the latest ILS/ Autolabel applicator pads, for instance, a new size and shape can be ordered and installed within weeks. Indeed, items including panel housings, blow nozzles, release buttons, applicator pads, extender plates, cable path guides and pivot knuckles have all been developed quickly and effectively and then introduced on the standard ILS/Autolabel print and apply systems. T 0161 655 4846 W www.ilsystems.co.uk Larger liquid systems were demonstrated at show V isitors to Karmelle at the PPMA Show found a bigger stand housing demonstrations of a range of the company’s larger equipment. Taking centre stage was a fully functioning three head rotary capper designed for closing various types of containers (made of plastics, glass and metal) with screw, press-on and/or pilfer proof caps. The machine is especially suitable for use in the food processing, cosmetics and chemical industries but as all of the machines are bespoke, it can be adjusted to suit other sectors. A number of smaller, A three head rotary capper from Karmelle is able to handle a range of packs interactive filling and labelling machines together with videos of its mini monobloc were also featured. This monobloc filler, capper and labeller has been designed to be installed in any restricted space as it covers only 2 x 1 metres. T 01484 533356 W www.karmelle.com 8 MACHINERY UPDATE PROMOTIONAL SUPPLEMENT Review of the Year 2015 Food actuators Food grade offer To-lo-matic’s IMA integrated servo motor actuators, the company’s most powerful integrated motor rod actuator, is now available from Motion Control Products with a food grade white epoxy coating and stainless steel components for wash down applications in the food and beverage industry. Available in four sizes, the IMA line of integrated motor rod actuators features stroke lengths from 76.2mm to 457.2 mm and peak thrusts from 890 to 30,594N at speeds up to 610 mm a second. “Many applications within the food and beverage industry require high-force electric actuators that can withstand the rigours of sanitary wash down,” says Steve McKay, md of Motion Control Products. “New IMA actuators with a food grade white epoxy coating and ingress protection rating of IP67 are an economical alternative to custom stainless steel actuators. The IMA actuator series is compact and durable. T 01202 599922 W www.motioncontrolproducts.com Dual Flash labelling unit can handle over 30 ready meals An offline flash labelling system from PrintSafe that is fitted with two label applicators has been installed at a ready meals producer to apply promotional flash labels and print date codes on sleeves for more than 30 different product lines. With two label applicators, promotional stickers can be applied to the top and side of unglued sleeves in just one pass while the high speed system can also be used to apply two different labels to a pre-glued cardboard sleeve. With the addition of an inkjet printer, the machine can also be used to print date codes in the same operation High speed flash labelling offer at between 240 – 500 sleeves per minute. T 01962 761761 W www.printsafe.co.uk Bottom seal flow wrapping machine offers hygienic operation with quick changeovers Nigel and Dianne at new UK office Cartoning company establishes in UK to better serve clients French carton packaging company Emballage Technologies continues to develop internationally and, having set up a subsidiary in Sweden four years ago, it has now opened in the UK under the name Etpack Sprinter UK. Based in Newbury, the carton packaging specialist is run by Nigel Redding and Dianne McIntyre who between them, have clocked up 40 years of combined experience in the carton machinery industry. The company offers a wide range of cartoning equipment as well as complete turnkey systems. It also supports all installed Sprinter technology throughout the UK with spare parts and also servicing packages. T 01635 905090 W www.et-pack.com Redpack’s bottom seal flow wrapper is IP65-rated Redpack has launched a new IP65-rated bottom seal flow wrapping machine which is designed to provide hygienic operation for users. The first machine has been sold to a company wrapping celery at speeds between 70 and 120 items a minute. Manufactured from stainless steel, the HC65 machine is designed to minimise bug traps with no flat horizontal surfaces and minimal celvis fixings and sealed structural sections to allow easy cleaning for operators. The design means it is able to withstand cleaning and washing with a low pressure hose. It also means the unit is easy to maintain. The Redpack HC65 discharge and infeed are manufactured to an IP67-rated specification. The discharge has been designed for quick removal from the flow wrapper, as has the infeed which has a cantilevered design with drop down side for easy and fast cleaning access and a quick release chain. Ideal for busy pack houses where downtime needs to be kept to a minimum, says the company. T 01603 722280 W www.redpack.co.uk