A digital service that gives instant visibility to filling levels in packaging machinery has been developed by SICK in collaboration with industry end-users. SICK Filling Level Monitoring avoids machine stoppages by giving real-time data to operators via smartwatch or phone, so that levels of carton blanks, adhesive or film wraps, for example, stay topped up. Instead of having to check each magazine or film roll level in person, machine operators monitor fill levels on their watch or phone and are alerted by SICK’s Filling Level Monitoring system before levels become critical. Machine downtime is avoided and staff walking routes can be planned efficiently to ensure optimum production uptime.   Industry Collaboration The SICK Filling Level Monitoring digital service can be used with any SICK smart level sensors. Its first applications have been developed with packaging manufacturers and machine builders using SICK DT-50 laser distance sensors to output level measurements from carton magazines and film rolls. The measurements are routed to a SICK SIM1012 edge gateway, which aggregates and forwards encrypted data via SICK’s LiveConnect digital interface, so that it can be easily accessed, managed, and processed online. The SICK Filling Level Monitoring cloud-based dashboard provides easy-to-interpret graphical information about the real-time status of machines from any internet-enabled device. Automatic push notifications on the fill levels can be set up for smart devices to alert with an acoustic signal and vibration. Meanwhile, production managers can monitor the fill levels of all machines across a packaging line, shift or entire production facility. Analysis of historic trends can be used to optimise production processes.   Unexpected Benefits Neil Sandhu, SICK’s UK Product Manager for imaging, measurement and ranging, said: “SICK worked closely with leading packaging end-users and machine builders in Europe to develop a cost-effective and easy-to-implement system. “By using the smart watch alerts, our customers found that fewer operators were needed to keep cartoning machines replenished, so staff could be deployed more efficiently to other duties. What’s more, the system brought unexpected benefits to overall production control. For example, the loads on packaging machinery lines could be monitored to identify over- or under- capacity.” While initially developed for cardboard and film packaging materials, Filling Level Monitoring can also be adapted for liquids including adhesives, or granular raw materials. It is also possible to add customised services and analyses tailored to particular machinery or processes. Up to six SICK sensors can be monitored by each SICK SIM1012 gateway, and more sensors, including third-party devices, may be added by connecting over OPC-UA.  Sensors are also continuously monitored by the system in case one should go offline or need a replacement. The solution can be extended to meet the needs of customers on request, e.g. to customise and display additional data on the dashboard.  Integration to third party ERP and MES software systems is also possible.   Digitilisation Neil Sandhu concludes: “Cloud-based services such as Filling Level Monitoring illustrate how making reliable sensor data transparent enables digitalised machine operation as part of Industry 4.0. By combining smart sensors with intelligent software, critical processes can be visualised in real time and adapted for the needs of users. “Early adopters are noticing new and unexpected production trends when they view and interpret their historical production data in easy-to-read graphical displays. As a result, they have been able to optimise production processes and deploy staff to achieve efficiencies never even expected.”

The Absolut Company, part of Pernod Ricard, is working with Blue Ocean Closures (BOC), a start-up based in Sweden, to develop an innovative natural fibre-based closure cap for Absolut Vodka’s iconic bottle. Made from bio-based materials, the cap’s pioneering design reduces the amount of plastic used in packaging by combining a body made of sustainably sourced FSC fibre material with a thin top-seal barrier layer, making it recyclable as paper and ocean biodegradable. Together, BOC and The Absolut Company will develop the cap for use on current glass bottles, as an addition to existing cap solutions as well as a possibility for future packaging innovations. The partnership will see several iterations of the cap through prototyping and testing stages in 2022, with plans to share it commercially in 2023. This is part of a wider ambition from The Absolut Company and Pernod Ricard to create a fully circular business, working with suppliers and partners to ensure that 100% of its packaging is reusable, recyclable or compostable by 2025. Speaking on the partnership, Eric Näf, director of Packaging Development at The Absolut Company, said: “We know that collaboration across the whole value chain sits at the heart of long-term progress and true environmental, economic, and social impact. As part of our circular way of thinking, we are delighted to be working with BOC to continue designing out single-use materials and using packaging innovation for the benefit of the planet.” Lars Sandberg, CEO of Blue Ocean Closures, said: “We are proud to partner with Absolut Vodka to bring an alternative cap solution to the market. My first job was actually on the Absolut Vodka factory floor, so I’ve seen how quality is a key focus across every part of the production process.” Ulrika Evermark, community manager at Blue Ocean Closures, said: “We are excited to welcome Absolut Vodka to join us in the important development of our caps, alongside industry leaders such as ALPLA and Glatfelter.”

Cathedral City, the Nation’s Favourite cheese from Saputo Dairy UK, has unveiled new side opening packaging, featuring the brand’s signature resealable, zip lock. The brand is the first in the UK to introduce side opening block cheese packaging which is resealable. Launching across the entire Cathedral City block range, the new packs will begin rolling out in stores from 13th June and will be available in all major retailers. Convenience is at the heart of the re-design, giving consumers the ability to seamlessly slide the cheese in and out of the pack without touching the bare cheese block, so they can slice or grate it straight from the packet. To help reduce food waste, the updated packaging keeps the cheese fresher for longer as the shorter zip makes resealing it even easier. It also reduces the plastic content by 6%, saving 40 tonnes of plastic a year. In consumer trials, over 60% of users preferred the new side opening format. 73% of consumers also agreed the zip lock would keep their cheddar fresher for longer and would be easy to open and reclose multiple times. Neil Stewart, Cathedral City Marketing Controller at Saputo Dairy UK, says, “Research has told us that consumers are looking for ease and convenience when using their block of cheese. Hygienic handling and the ability to keep the cheese as fresh as possible were also key considerations and our new side opening, resealable packs achieve all of those things. The fact we are the first brand on the market to introduce such a pack demonstrates the commitment, passion, and expertise that we at Cathedral City put into everything we do. “We will always listen to our customers and their feedback and, as such, the packaging will continue to feature the press to close ability that not only keeps our cheese fresh and helps to reduce food waste, but also eliminates the need for secondary plastic to reseal the cheese once opened.” The new packaging, which follows the brand’s recently relaunched design, will be replacing Cathedral City’s current top opening packs. Last month Saputo Dairy UK revealed a new brand identity for Cathedral City featuring a modern, redesigned city scene around its iconic cathedral and new, vibrant SKU-specific colourways to complement its signature burgundy.