< Previous20 Food & Drink International www.fdiforum.net END OF LINE PACKAGING Mini Air Pro WƌŽƚĞĐƟǀĞ air cushion system, producing 100% recyclable air cushion on demand an employee-owned business kitepackaging.co.uk 100% recyclable material Air cushioning for ƵůƟŵĂƚĞƉƌŽƚĞĐƟŽŶ /ŶŇĂƚĞĚŽŶĚĞŵĂŶĚ requiring less storage space 900m roll equivalent to approx 10 rolls of large bubble wrap Mini Air EasiMini Air Classic Entry level system producing air cushion on demand &ŽƌƵƐĞǁŝƚŚϭϬϬйƌĞĐLJĐůĂďůĞĮůůĞƌΘǁƌĂƉƉĞƌĮůŵƐ ĂŶƌƵŶƵƉƚŽϴŵŽĨĮůŵƉĞƌŵŝŶƵƚĞ Ideal for under 100 parcels per machine per day Mid-level system producing air cushion on demand &ŽƌƵƐĞǁŝƚŚϭϬϬйƌĞĐLJĐůĂďůĞĮůůĞƌΘǁƌĂƉƉĞƌĮůŵƐ ĂŶƌƵŶƵƉƚŽϴͲϭϴŵŽĨĮůŵƉĞƌŵŝŶƵƚĞ Ideal for 100 - 400 parcels per machine per day Advanced system producing air cushion on demand &ŽƌƵƐĞǁŝƚŚϭϬϬйƌĞĐLJĐůĂďůĞĮůůĞƌΘǁƌĂƉƉĞƌĮůŵƐ ĂŶƌƵŶƵƉƚŽϯϮŵŽĨĮůŵƉĞƌŵŝŶƵƚĞ Ideal for over 400 parcels per machine per day 02476 420068 Includes 1 free roll ŽĨϰϬŵĮůůĞƌ and 40m wrapper tŝĚĞǁƌĂƉƉĞƌĮůŵ available processing, to packaging right through to delivery. Yet, there are constant developments taking place which improve upon current wrapping machines, robots and rotating arms to achieve a greater efficiency, operate more sustainably and protect bottom lines. This can be a daunting task at first glance. How can a process which is not only going to cost money, but also significant investment in machinery – make the product cost less? The answer is simple and complex at the same time, with good planning. It is still more common than not for food products to be transported by road by lorry. In these cases the biggest investment often comes from fuel, with the item that a company is buying essentially being the empty space in the back of the vehicle. The problem comes from the fact that in many cases, all of this space cannot be utilised. The weight of products will push down on those © Shutterstock /Supanee Prajunthong 18-25.qxp_Layout 1 24/03/2020 15:02 Page 3Food & Drink International 21 www.fdiforum.net END OF LINE PACKAGING UK aftersales spares and service support provided. www.robopac.co.uk Robopac, Unit 7 – 8 Highfield Parc, Highfield Road, Oakley, Bedfordshire, MK43 7TA Tel: 01234 825050 Fax: 01234 827070 Email: sales°ÕJÀL«>V°V Turntable Wrapping Machines Rotating Arm Wrapping Machines Case Sealers & Erectors Self-Propelled Robot Wrapping Machines Horizontal Wrapping Machines See us at Stand J60 stacked beneath them, often damaging products beyond what can be sold in a retailer. Obviously, this is unacceptable, and thus it is not uncommon for space to go unused in the back of a vehicle. This is empty space that has been paid for. Strong and rigid end of line packaging can help prevent this, strengthening and protecting the product so that more of it can be stacked without damage and thus be stacked taller. This is particularly prevalent in the food and drink industry due to how fragile many foodstuffs are, from biscuits to crisps, ready meals to cakes. Stronger end of line packaging can protect them during transit, while also diffusing the weight of additional boxes down supporting frames. If twice as much content can be placed into a single vehicle, then in theory it should allow for a fifty per cent saving on transport costs (or at least fuel). Some of the most significant developments to the packaging industry aren’t whole machines, but rather sensors. Given the increased demands from the industry, which need to correspond to changes in consumer taste and habits, as well as legislative changes, sensors need to be up to the task. Therefore, the very latest sensors and sensor systems need to be designed for complex, frequently changing tasks while also meeting ever more demanding brand protection, safety and documentation requirements. Working in conjuncture with sensors is the use of offline case marking. Implementing such a strategy greatly reduces the human error which in turn bolsters efficient practices and decreases the risk of damaged goods and loss. The ability to mark-up secondary packaging offline meets a growing need in today’s grocery market, where the emerging retail channels of discount, convenience and online will account for all the growth over the next ten years as conventional supermarkets decline. For many food operators, this shift is driving a rapid rise in the complexity of their logistics operations as demand grows for mixed cases and little-and-often deliveries to a wider range of locations. This balancing act must be taken further, however, and it’s always important to keep the end user in mind. While saving money on fuel – and thus environmentally as well – might sound nice, the enthusiasm will rarely reach the workers in the warehouses of supermarkets, who will not appreciate packaging that is difficult to get into. Rigid and unyielding end of line packaging that might have been good for protecting the product from strain, will not always be the easiest to break apart for the shelves. Unless it is specifically designed to be so, that is. Product display packaging and trays have helped to minimise this problem, with many forms of transport packaging actually transforming into display packs with relative ease. What manufacturers are more focused on today, however, is how far 23 Á 18-25.qxp_Layout 1 24/03/2020 15:02 Page 4THE COMPLETE PRODUCTION LINE EVENT See the latest processing and packaging machinery, robotics and machine vision in action Network with industry peers and gain valuable insight at our must attend seminars FREE TO ATTEND REGISTER NOW ppmashow.co.uk 29 SEPT - 1 OCT 2020 NEC, BIRMINGHAM OWNED AND ORGANISED BY PPMA 2020 Show Advert V4.indd 121/11/2019 14:41 18-25.qxp_Layout 1 24/03/2020 15:02 Page 5Food & Drink International 23 www.fdiforum.net END OF LINE PACKAGING High Speed Robotic PalletiserHigh Speed Open Mouth Bagger • Automated Systems • Superior Performance • Innovative Design • Advanced Technology www.fischbein.com sales@fischbein-saxon.co.uk Tel: 020 8344 6600 Automate with Confidence automation can be incorporated and how complex that task might be. Can the packaging systems be efficiently integrated into a line in such a way as to boost the efficiency of the process? Too often does it seem that the manufacturing line and the supply chain are separated by a wrought iron fence, with many accidents happening in transit between The increased automation of this process can also cause problems in its own right. Most notably, in a high-speed packaging and labelling operation at a bottling plant, un- or mislabelled packs have to be detected by the human eye or by additional scanners, removed, returned and relabelled. In a competitive high- volume market, where product cost is low and margins are squeezed, this handling Keep calm and relax … and recycle Epsom Salt relaxes the nervous system, alleviates aching limbs, relieves back and muscle pain and cramps, cures skin problems, treats congestions and colds, heals cuts and draws toxins from your body. The Epsom Salts Company wanted to offer a pack that was 100% recyclable and owner John Richardson said, “National Flexible provided the ideal solution”. New oriented PE is the perfect material for those companies wanting a single polymer solution which can be recycled at supermarket recycling centres. National Flexible can now supply OPE pouches and films both single web and laminates. This environmentally-friendly solution is low cost, low weight, recyclable, versatile with a low carbon footprint. For more information, email carol@nationalflexible.net. 24 Á © Shutterstock /Ari Wid 18-25.qxp_Layout 1 24/03/2020 15:02 Page 624 Food & Drink International www.fdiforum.net END OF LINE PACKAGING Harkstead Hall Barn, Harkstead, Ipswich, Suffolk IP9 1DB Tel: +44 (0)1473 893990 Fax: +44 (0)1473 893995 email@penn-packaging.co.uk www.penn-packaging.co.uk • Case/tray Packing machines • Shrink Wrapping systems • Stretch-Film Wrappers • Depalletisers • Palletisers • Bag Closing Machines • Pillow pouch systems • Pre-made pouch • Stand-Up / Doypack • Slider/Zipper • Spout • Ultra Clean Filling SICK’s SIG200 is an IO-Link Master and Control System in one SICK has unveiled its SIG200 PROFINET Sensor Integration Gateway, the first in a family of intelligent Industry 4.0 gateways designed to work as both IO-Link Masters and small, distributed control systems in one. It makes light work of configuring localised sensor applications as part of food processing, packaging and bottling machinery, while unlocking access to valuable process and performance data from the sensors to enterprise-level and cloud-based systems. “Engineers will find it easy to configure and visualise an automation solution with the SICK SIG200. The logic editor has a great drag and drop function so you can visualise all the connected sensor and actuator signals and measured values without the need for special software knowledge. It saves a huge amount of programming time, effort and cost,” said David Hannaby, SICK’s UK Product Manager for Presence Detection. For more information, visit www.sick.co.uk. © Shutterstock /Siwakorn1933 adds to costs. This is especially the case when the line has to deal with many different products with a range of sizes and shapes - all of which remains the manufacturer's duty. This places some burden on scanning and detection equipment, which must be more robust than ever. Of course, one company's problem is another's opportunity, so those who are able to adapt and manage such difficult conditions will be in a position of competitive strength over their rivals. What one company classes as an end of line packaging system will also differ greatly from another's, creating a situation in which one size certainly does not fit all. Some companies have chosen to specialise in entry-level systems, which have lower levels of investment but tend to be somewhat more labour intensive. These can be more suitable for individual lines, however, particularly for handmade or low-quantity production lines. 18-25.qxp_Layout 1 24/03/2020 15:02 Page 7Food & Drink International 25 www.fdiforum.net END OF LINE PACKAGING Label | Print | Apply Looking to automate your beverage labelling? The ICE Vulcan Print & Apply Labeller is up to 10x faster than hand applying, for a rapid ROI. Book a demo today, we’ll bring the ICE Vulcan to you. 01159 640144www.interactivecoding.co.uk/vulcan-lpa T he beverage and bottling factory environment faces many challenges: as the drinks industry diversifies and seasonal demands peak, productivity increases and frequent product changeovers are often required to keep up with supply chain demand. Legislation changes and increasing labelling requirements also means that there is more information to physically code onto both primary and secondary packaging. In addition to industry challenges, as the world takes on carbon footprints and energy usage is under the spotlight, measurements such as OEE are being used to put factory efficiency targets in place to keep lines running as efficiently as they can be. Downtime is no longer an option for many operations. But what if your secondary packaging application can’t meet new and ever-changing demands? Don’t let your labelling solution become the bottleneck of your production line. The solution is the ICE Vulcan print and apply labelling machine. Controlled by intelligent motion™ technology, the ICE Vulcan has 80% less wear parts than traditional labelling solutions, so there’s no slipping, or manual adjustments required, reducing downtime dramatically. The first-of-its-kind to print and directly apply labels in one continuous action negates the need for an applicator. Ultimately meaning that the ICE Vulcan can apply labels at up to three times higher speeds than traditional solutions, keeping up with the rest of the production line, without ever missing a pack. Ready to improve your factory uptime? Discuss your secondary packaging requirements with one of Interactive Coding Equipment’s coding and labelling experts today on +44(0) 1159 640144, or e-mail us on enquiries@uk.interactivecoding.com, or by visiting www.interactivecoding.co.uk. Don’t let your labelling solution become the bottleneck of your production line 18-25.qxp_Layout 1 24/03/2020 15:02 Page 826 Food & Drink International www.fdiforum.net SMURFIT KAPPA Q&A We spoke to paper-based packaging specialist Smurfit Kappa Machine Systems about the company’s new direction, the important of automation and sustainability, and how it offers customers a one-stop shop. Can you tell us more about Smurfit Kappa Machine Systems new direction? Smurfit Kappa Machine Systems is a unique business; as well as the group’s ability to design, manufacture and supply corrugated packaging, we also design, develop, manufacture and supply packaging machinery. We have deep, proven experience in corrugated board and packaging machinery design – we’re not just a machine supplier, but an expert in corrugated board and machinery. With us, customers get a one-stop shop so this ‘relaunch’ or ‘new direction’ is really about conveying everything we do and what we can offer. It’s about refocusing on our expertise and signalling to the wider industry our ambitions to branch out in new directions going forward. A big part of that is our sustainability efforts. Over the years we’ve built a reputation for very robust engineering and the machines we develop and build promise longevity – we can say that without any doubt’ as we build everything ourselves from the ground up. We don’t outsource anything, and handle designing, building, installing and servicing ourselves. In this way we have an on-going relationship with our customer’s right across the product lifecycle. Of course, our unique selling point – and, indeed, a major draw for our customers – is that we specialise in both the corrugated packaging and the machinery. It’s a bonus for end users, as if there’s a problem, it’s our problem, we take full responsibility for the complete unit. How is the company responding to the environmental agenda and incorporating sustainability? As with other areas of the supply chain right now, sustainability is a huge part of our focus. We’ve aligned ourselves with climate goals and are playing our part to get plastic out of seas and reduce overall plastic pollution levels. Board packaging is crucial to this approach moving forward. Packaging holds a valuable, sustainable role in guarding against waste and through Q&A Smurfit Kappa Machine Systems 26-27.qxp_Layout 1 24/03/2020 15:04 Page 1Food & Drink International 27 www.fdiforum.net SMURFIT KAPPA Q&A our initiative, we will use our strength in sustainable materials, packaging design, packaging recycling and industry leading expertise to develop more sustainable packaging solutions for our customers, our planet and ourselves. For customers looking for a sustainable alternative to plastic packaging, we have a solution. Already we’ve replaced plastic packaging with more sustainable board solutions. What can your machinery and packaging offer customers? When customers come to us, it’s all about finding out their requirements and ensuring that our design fully meets those needs. Customers appreciate the fact that we actually sit down and listen to them and are able to provide a machine that meets their exact specifications. It’s really no surprise that, over the years, we’ve cultivated this reputation of excellence and why we have so many satisfied customers. Retailers all have different requirements and that’s a major factor when it comes to designing and manufacturing case packaging solutions. Our machines are designed to be extremely flexible in the outer case styles that can be accommodated, whether that’s a one-piece outer pack with shelf ready features, or a two piece tray and lid solution, it’s all in one machine. We’re well placed for developing new pack styles for retailers and we pride ourselves at being at the forefront of corrugated packaging. The same goes for machinery, we’re tried and trusted, and all our machines are supplied with a guaranteed efficiency. We also recognise that, obviously, labour is a big cost and that’s a big concern to our customers. That’s where automation comes in, taking human interaction out of the equation. Obviously this leads to lower production costs, but it means higher output and more efficient processes for manufacturers. How do your corrugated board and machinery divisions work together? Although our corrugated and machinery divisions are, ostensibly, separate divisions with separate design teams for each, they work in harmony. Colleagues within corrugated packaging design and develop new pack styles and then the machinery division designs, develops and builds the machines needed to erect that packaging, whether that be a standalone machine for forming the pack, or a fully automated solution for automatically collating and loading the primary pack into the corrugated case. It’s very much a two-way relationship that, again, really makes us unique and sets us apart. As we’ve already said, there’s a real harmony between the two divisions. It’s important to machinery designers to understand the corrugated manufacturing design process and vice versa. In this way they can understand the problems with the corrugated manufacturing process and production and therefore build that flexibility into the machinery, eliminating potential issues down the line. As well as playing off one another, the divisions also get leads from customers. For example, a customer might come to the board division with specifications for a new type of package that the team will then design and develop. Smurfit Kappa Machine Systems will then respond by creating the machinery needed to make that packaging a reality for the customer. At the end of the day, it’s all one company and we all work together for the benefit of our customers. Given our forty-year history, we’ve got a lot of experience in this business, making us a business with a personality and that’s only possible thanks to our people – and our customers really respond to and recognise that. To find out more, visit www.smurfitkappa.com/uk. 26-27.qxp_Layout 1 24/03/2020 15:04 Page 228 Food & Drink International www.fdiforum.net GEARS, DRIVES AND CONTROLS © Shutterstock /Shutter_M Driving forward control and efficiency Manufacturers of gears, drives and controls are seeing increasing demand for more intelligent, connected, components. 28-31.qxp_Layout 1 24/03/2020 15:05 Page 1Food & Drink International 29 www.fdiforum.net GEARS, DRIVES AND CONTROLS Food manufacturers are constantly looking to make production ‘smarter’. The gears, drives and controls sector is one key area in which advances are being made to enable this desire. Intelligent technology and the Internet of Things (IoT) have allowed equipment manufacturers to create information-enabled machines, permitting high levels of connection between devices so that operations can be examined and optimised easily, and heightened automation. When it comes to today’s gears, drives and controls, customers are asking for Industrial Internet of Things (IIoT) compatibility, increased efficiency and speed, improved data manipulation and better process control. Food producers want more control over devices and machines, to amplify production and quality, and access to real time data on the conditions and activity of their facilities. Thanks to progress in communication and network technology, connectivity in this realm has been bolstered. Today’s drives can be enhanced significantly, with the ability to integrate predictive analytics and maintenance, real-time energy usage data and active condition monitoring, which ultimately offer insight from which one can boost productivity. Modern drives present detailed condition information in real- time, on drives themselves and associated motor operations. This facilitates dynamic planned, or predictive maintenance, rather than waiting for failure or sticking to a fixed maintenance period. Drives featuring built in predictive analytics are indispensable in their ability to prevent costly unplanned downtime. Combined with self- monitoring faculties and new digital platforms, modern drives can predict the lifespan of various components, taking into account a whole host of factors. Notifications will then be sent to maintenance teams when a component is reaching the end of its feasible use, so that replacements can be fitted without dealing with unscheduled downtime. Going further, connected systems can also check automatically if a facility has the required replacement parts to hand, and order them if this is not the case. Connected drives also hold enhanced adaptive control abilities, to monitor machines and factors like vibration, which may alter over time, and compensate for this. The data stemming from connected, self- monitoring drives can be used to bolster operational efficiency and safety of machinery. It is crucial that food and drink producers have condition monitoring programmes in place in the battle to reduce unexpected downtime and improve overall equipment efficiencies. With vibration analysis, infrared thermotography, oil sampling, visual inspections and ultrasound, maintenance need be no struggle and failed gearboxes and drives avoided. Energy efficiency is another key trend impacting the gears, drives and controls sector, as customers look to reduce emissions and costs. To meet these desires, variable speed drives (VSDs), variable frequency drives (VFDs) and high efficiency motors are being utilised to curb energy consumption and make marked savings. Electric motors, which consume a large amount of energy, are being adapted with VFDs, which hold greater speed control - able to adjust motor speed based on demand - to address potential mechanical stress damage, and can be set to a precise torque limit to avoid overloading, stop overuse and beneficially reduce expected damage that builds over time. VFDs can improve production and efficiency overall in food facilities. Compared to, say, an AC motor, which during initial start-up puts a major strain on a power supply line and runs at full speed, VFDs do not face this problem as the voltage begins at zero, increasing slowly, picking up speed to manage strain on power supply lines. VFDs present high levels of control to operators with acceleration controls, to maintain motor strength, and deceleration controls. This aspect can also offer a chance to remove gearboxes. When it comes to motors, to ensure ultimate efficiency, equipment manufacturers should look to achieve IE4 (super premium efficiency) and IE5 (ultra-premium efficiency) energy efficiency classifications. Motors within these classes significantly reduce electricity use and CO2 emissions, with a noted relatively short payback time from installation. When paired with a variable speed drive, tighter controls can yet be ensured. 30 Á 28-31.qxp_Layout 1 24/03/2020 15:05 Page 2Next >