Rockwell helps wrap up packaging line optimization

Food & Drug Packaging, March, 2005

What does "packaging line optimization" mean? Getting the most out of your packaging line involves many factors. Reducing downtime, speeding changeover, minimizing scrap, increasing throughput, and expediting maintenance are just a few of the considerations.

In short, packaging line optimization means making machines work as intelligently and efficiently as possible. Rockwell Automation specializes in components, software and services that allow both original equipment manufacturers (OEMs) and end users to accomplish this goal.

Rockwell is the largest company in the world focused solely on automation. An array of industrial control hardware and software, sensors, instruments, motors and other equipment can help bring efficiency to new heights. Rockwell Automation hardware and software combined with expertise delivering optimization solutions for packaging lines helps ensure that packaging machinery is as smart as possible when it gets in the door, and that it operates as efficiently as possible.

"Rockwell Automation's ability to deliver value with packaging line optimization can be divided into two broad categories," says Charley Rastle, Rockwell's food industry solution marketing manager. "The first is making every packaging line as flexible and agile as possible at the point of deployment. The second is monitoring established lines to identify and resolve problems."

Flexibility is vital

"Flexibility is one of the most important attributes of a modern-day packaging line," Rastle says. "Not only do many lines have to handle a variety of container shapes and sizes, but there's often a rush to get the latest varieties to market.

"One of the things that's impacting [packagers] in their new product introductions is, 'How long is it going to take me to make changes to my control system so I can get that new product up and running?'" Rastle says.

The two-word answer to that question: Integrated Architecture.

Until about 10 years ago, most packaging machines coordinated their varying motions through mechanical means. Cams, drive shafts, gears, belts and other components provided mechanical linkage among a machine's different "axes of motion"--that is, the different actions that various machine parts have to take. Mechanical linkage worked well but was inflexible; usually, only one set of motions could be built into it.

But as the price of servo motors came down, equipment manufacturers started using them as an alternative to mechanical linkages. Servo motors are digitally controlled and give constant feedback on position and speed. This precise control enables them not only to work together, but to change the way they work together instantly. This greatly simplifies changeovers and increases flexibility.

Servo motors, however, pose their own demands. The axes of motion must be coordinated carefully, both within and between machines. If the control system for packaging machinery is not integrated, it leads to complications. End users could find themselves having to reprogram (or paying someone to reprogram) the controllers for individual motors, motion control, and other discrete functions.

But Integrated Architecture is a way around that difficulty. Rockwell Automation's ControlLogix line of controllers form the basis for Integrated Architecture. Machines that use ControlLogix can adjust to different requirements via a single set of commands, transmitted through a single controller.

"We're hearing great things from OEMs about how it helps them be more efficient in building their machines," Rastle says.

Axes of motion

For instance, a case packer is a typically a complex packaging machine, with multiple axes of motion required to set up blank cases, collect the packages or other individual units, deposit them in the case, seal the case, and perform other functions. Under a single-architecture system, pre-defined motion control commands make servo motion programming simple. Once the basic movement commands are programmed, engineers can duplicate them for other axes in the program, dropping them in where appropriate.

It's not just OEMs who benefit. The flexibility conferred by the ControlLogix platform makes changeovers easier once a line is installed. "It allows people to make the changes quicker for new product introductions," Rastle says.

Identifying and solving problems that appear on the packaging line is the second broad area in which Rockwell Automation products and solutions can help. The key is to collect the right kind of information in real time.

"If you want to improve your line, what you want to do is not only collect data, but be able to view and analyze the data to improve operations," Rastle says.

This information includes breakdowns, jams and other problems. Under the Integrated Architecture used by ControlLogix, such data is easily accessible for collection into a system database such as Microsoft's SQL Server. Having the information in an accessible, easily organized form allows end users to do a root-cause analysis of their problems.