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packagers playbook serieseducation for packaging professionals 2012 Edition
8 Cartoning through stretch wrapping 8 Packaging equipment project strategies
8 Glossary of terms 8 Downloadable vendor evaluation tool
END-OF-LINE
EQUIPMENTPlaybook
HOW TO SUCCESSFULLY
IMPLEMENT
ENd-OF-LINE PaCkagINg
EqUIPMENT PROJECTS
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packagers playbook serieseducation for packaging professionals
SPONSORED BY2012 Edition
http://www.focke.com/http://www.econocorp.com/http://eastey.com/http://www.diagraph.com/http://www.douglas-machine.com/http://www.domino-na.com/http://www.delkorsystems.com/http://www.palletizing.com/http://www.camagroup.com/http://www.bpa-flexolutions.com/http://www.bergamiusa.com/http://www.abcpackaging.com/http://www.abb.com/roboticshttp://www.arpac.com/http://www.aagard.com/ -
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packagers playbook serieseducation for packaging professionals
SPONSORED BY2012 Edition
iconotechGeneric Case Printers
http://www.iconotech.com/http://www.iconotech.com/http://www.iconotech.com/https://www.xpedx.com/packaging-solutionshttp://www.wexxarbelmachines.com/http://www.videojet.com/http://www.gerhard-schubert.com/en/schubert-grouphttp://www.squidink.com/http://www.toptier.com/http://www.optima-usa.com/http://www.pearsonpkg.com/http://www.nordson.com/http://www.mgsmachine.com/http://www.iconotech.com/http://www.hartness.com/http://www.kukarobotics.com/http://www.hbfuller.com/liquamelthttp://www.graphicpkg.com/http://www.foxjet.com/ -
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End-of-Line Packaging Equipment Playbook
CONTENTS4 / 100
INTRODUCTION
8 Your playbook or building a better packaging line
CONTRIBUTORS6 Brand owners, consultants and engineering experts
contributing to this playbook
10 Best practices or buering and end-o-line design
13 Eight tips or selecting cartoning equipment
17 Ten tips or buying coding/marking equipment or cases and pallets
23 Trends in case packing equipment28 Checklist or buying case packing equipment
31 Best practices or selecting case packing equipment
35 Wraparound versus RSC cases
36 Glossary o case packing terms
44 Nine tips or selecting multi-packing and shrink bundling equipment
48 What to look or when selecting palletizing equipment
EQUIPMENT STRATEGIES
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End-of-Line Packaging Equipment Playbook
CONTENTS5 / 100
PROJECT STRATEGIES
58 Ten nancial justications or new equipment
62 Best practices or speciying packaging machinery
69 Vendor evaluation methodology or packaging equipment
71 Tips on nding the right equipment supplier
78 Roadmap or a successul Factory Acceptance Test
86
Ten tips or a successul packaging line start-up91 Automation trends strategies or packaging machinery
96 How projects ail: 11 pitalls to avoid
52 Trends in robotics and best practices or buying and speciying
55 Best practices or speciying stretch wrapping equipment
EQUIPMENT STRATEGIES (CONTINUED)
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End-of-Line Packaging Equipment Playbook
CONTRIBUTORS
Paul ZePf
P.Eng., M.Eng., CPP
Zarpac Inc.
With nearly 40 years o packaging production
experience, Zep has written 14 books on packaging
production technology and is a co-ounder o Zarpac
Inc., an engineering, sotware, and consulting frm.
Paul Redwood
Sr. Research Engineer
Church & Dwight
Shawn fRench
Engineering Director
Dannon
Matthew couRteSiS
Packaging Dept. Supervisor
Boston Beer
Sunny iShikawa
Engineering Research Fellow
Wrigley
GReG flickinGeR
VP Manuacturing and Corporate Engineering
Snyder's-Lance, Inc.
The ollowing brand owners, consultants and engineering experts contributed to this playbook
adaM PawlickDirector o Packaging
Bay Valley Foods
Glenn whiteSide
Packaging Engineer, CPP
Synthes (USA)
dave hoeniG
Principal
DH Technical Consulting, LLC
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End-of-Line Packaging Equipment Playbook
CONTRIBUTORS
We grateully acknowledge the expertise othese supplier contributors:
All-Fill, Cozzoli Machine Co./MRM/Elgin, Delkor Systems, Douglas
Machine, Econocorp, Inc., EDL Packaging Engineers, Fanuc Robotics,
Grin-Rutgers, H.B. Fuller, Hartness, Intelligrated, Lantech, MGS
Machine, Pearson Packaging Systems, Schneider Packaging
Equipment, Spee Dee Packaging Machinery, Videojet, Yamato
Several other brand owners were interviewed
or this playbook on the condition o anonymity.
SteRlinG anthony
Consultant
toMMy lancaSteR
Chie Operating Ocer
Bryson Industries
cuRtiS waRdauGh, P.e.
President
Medalist Engineering, P.C.
Additional contributors:
Keepcurrentwithafreeprint
subscription!
330 N. Wabash Ave., Chicago, IL 60611 phone 1-800-355-5595 www.summitmediagroup.com
www.packworld.com/subscribe
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End-of-Line Packaging Equipment Playbook
INTRODUCTION
RETURN TO CONTENTS
By david newcoRn
VP/Digital & Custm Mdia
Packaging World
Your playbook or buildinga better packaging line
Anyone whos worked in packaging machinery engineering knows that speciying and
installing a modern, automated packaging line is essentially an exercise in eective
management o literally thousands o details. As little as one misplaced assumption can
delay or sink the project. No wonder projects can be overwhelming at times to even themost seasoned proessionals.
Thats why we conceived this Playbook. We wanted to create one source that spells out all
the tricks and tips associated with buying, testing, commissioning, and starting up packaging
equipment. To unlock these secrets, we spoke with or consulted with over 45 sources. Most
o these consisted o in-depth phone interviews with experts in the eldengineers and
managers at leading consumer packaged goods companies.
We also talked to suppliers, who gamely set aside their sales hat and spoke honestly about
best practices and pitalls to avoid. Remember that while you may buy one ller or inspection
system or coding/marking system in a given yeari that manythe companies selling
that equipment have been through dozens o projects in that same time period. Learn rom
their experience.
http://www.packworld.com/playbook/forward/end-of-linehttp://www.accelacomm.com/jaw/source/67/50112540/http://www.accelacomm.com/jaw/source/67/50112540/http://www.packworld.com/playbook/forward/end-of-linehttp://prevpage/ -
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INTRODUCTION
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In short, what youre reading is the collective thinking o an industry, representing hundreds
o years o packaging experience, distilled into a short, actionable, bulleted style that makes
or easy reading.
This particular playbook is brand new or 2012, coming on the heels o our successul
playbooks in the area o fexible packaging, labeling and package development (all o
which are updated or 2012, by the way). In this playbook, we cover the back hal o the
packaging line, rom cartoning, case packing, and shrink bundling through palletizing
and stretch wrapping. You will denitely want to download the Primary Packaging Line
Equipment Playbook, which covers everything on the ront hal o the packaging linerom
unscrambling through induction sealing. The two playbooks will equip you well or your next
project. (See all our playbooks atPackworld.com/playbook.)
All o our playbooks are designed to be read either on the screen, or printed out.
A nal word. The entire cost o producing and distributing this playbook has been
underwritten by the companies who have sponsored it. We thank them or their support,and we thank you or reading.
continued
Your playbook orbuilding a betterpackaging line
http://www.packworld.com/playbook/forward/end-of-linehttp://www.accelacomm.com/jaw/source/67/50112540/http://www.packworld.com/playbookhttp://www.packworld.com/playbookhttp://www.packworld.com/playbookhttp://www.packworld.com/playbookhttp://www.packworld.com/playbook/forward/end-of-linehttp://www.accelacomm.com/jaw/source/67/50112540/http://prevpage/ -
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End-of-Line Packaging Equipment Playbook
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Best practices or bueringand end-o-line design
There are some special considerations or packaging line buering as it relates to the
end o the line:
1. Set increasingly high capacity downstream. A rule o thumb is or the rstmachine upstream to have 110% the capacity o the second, and so on, at by intervals o
10%. I calculations show that a piece o modern equipment has 95% availability, this can
be pared to allow the downstream machine to draw product away at 5% aster when run in
a catch-up mode to avoid back-ups. A 150/min bottling line that experiences ve minutes o
downtime will need downstream equipment to absorb 750 bottles. The key is to have 20%
to 40% extra speed and capacity downstream to allow the line to catch-up ater a downtime
incident. Over-speciying downstream capacity is a key to recovering rom stoppages. It also
helps smooth out system fow perturbations.
2. Find the lines sweet spot by determining the process centerline.Some lines run best at breakneck speed; others are most ecient at a slow and steady
pace. Practitioners o the manuacturing and packaging art oten make the mistake o
setting speeds too high, too close to design specications. One ailure can be disastrous to
productivity. Installations vary, but trial and error become evident when you document your
ByBoB SPerBer,
Spcial Pjcts edit
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End-of-Line Packaging Equipment Playbook
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continued
Best practices or buering
and end-o-line design
What Can Bergami Do For You?
610.588.3900www.bergamiusa.com
INNOVATIVE PACKAGING
MACHINERY SOLUTIONS
Cartoning Systems
Intermittent or Constant Motion.
All Speeds and Applications.
Wrapping/Bundlewrapping Systems
All Speeds and Multiple Applications
Fully Automated Casepackers
Vertical and/or Side Loading as Required
Casepackers-Palletizers Combinations
Ultra Compact Footprint
Palletizing Systems
Single Pallet Systems or Multiple Pallets Multiple SKU
Laser Guided Pallet Handling
and Complete Warehouse and Material Automation
results to arrive at the optimal combination o speed and
product quality on a balanced line with minimal upsets or
downtime. Trained personnel can choose rom a wide array
o statistical analysis tools to arrive at the right speed or
your equipment and overall line.
3. Leave sucient space between machines.Just as automated lines are oten set to run too ast,
machines on automated and highly integrated lines are
oten spaced too closely to one another. I automation
isnt state o the art and ully trusted, plan sucient space
between machines and stations to allow or placement
o buer zones. Designing in reliable unit operations can
help to minimize buering requirements, so i foor spaceis at a premium, ocus on equipment reliability, especially
generous tolerances or material variations.
4. Prevent stoppages at the case packer. Casepackers can be sources o ineciency, as seen in situations
where corrugated or gluing ails to meet specications.
This can back-up upstream processes and cause upstream
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End-of-Line Packaging Equipment Playbook
EQUIPMENT STRATEGIES
line stoppages and reworks, wasting all the eorts to
maintain high production eciencies upstream. Buering
can be minimized or eliminated when o-spec product and
materials are quickly, automatically inspected and rejected
rom the line to prevent hiccups. Bear in mind that it can be
very dicult to put containers back into a close-coupledline without knocking over other containers and causing
urther problems. Choose your case packing solution well,
with reliability carrying just as much importance as speed.
5. Dont let your accumulator reach topcapacity. For some accumulators, such as a verticalcarton accumulator, a completely lled accumulator
requires the line to be stopped and cartons to be unloaded.I theres not enough foor space to unload them, or i the
downstream machine isnt suciently ast, you may nd
your line running an empty ller.
Remember reliability is king and buering is your
insurance policy.
continued
Best practices or buering
and end-o-line design
A leader in the packaging world, Eastey Enterprises has been
making the industrys avorite shrink packaging equipment or
over 25 years. Our products are MADE IN THE USA so expect
eatures like all-welded rames made o 1/4 cold-rolled steel,
casted seal heads equipped with double locking bolts, and
proven quality and reliability to keep your packaging line up
and running day ater day.
Contact Eastey today and discover your frst and last choice in
shrink packaging equipment.
(800) 835-9344www.eastey.com
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Eight tips or selectingcartoning equipment
Here are some tips to keep in mind when purchasing cartoning equipment:
1. Know thysel. Choose cartoning equipment based on how it works in your specicplant, with your compressed air system, and with your blanks.
2. Consider the nature o the product when choosing either vertical orhorizontal equipment. The product will dictate the type o cartoning machine needed.For example, i the product is ree fowing (granular in nature like detergent powder or loose
pieces like boxes o cough drops), you may be able to ocus mainly on vertical-style cartoning
equipment. However, or products that can load horizontally or vertically, horizontal
equipment is oten better. Most cartoning machines are horizontal loaders. Generally, they
perorm with more fexibility at a lower cost.
3. Determine the most productive speed. First determine i the operation willbe on line or o line. For on-line speed, calculate the maximum rate possible to make the
product and divide it by the number o products per carton. Then actor in surge capability:
the potential to increase the rate via new processes or technologies. For o-line speed,
consider the daily, weekly, or monthly shipping quotas. Make sure to use realistic numbers or
days per week and true hours per day to calculate required cartons per minute.
By MaRty weil
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continued
Eight tips or selecting
cartoning equipmentThe confectionery plant "Ozersky Souvenir" is oneof the largest manufacturers of confectioneryproducts in Russia.
All sweets are being produced on advancedequipment of European manufacture. Exclusivetechnologies are developed and applied atOzersky, that along with special attention given tousage of natural raw materials, allow to createproducts of the highest quality with unique taste.
The customer consequently turned to CamaGroup, a leading supplier of advanced technologysecondary packaging systems, to engineer its
packaging lines to allow the company to meet theexceeding market demand.
To meet the customers needs the Cama packagingline is composed of four in line Triaflex DeltaRobots, which by means of a smart vision systemcan pick loose, naked candies, covered inchocolate, coming randomly from production lineand position them correctly on continuous motionconveyors in a pre-set pattern. Products areselected, according to their dimensions and thenplaced on two external conveyors. The maximuminfeed rate is 360 chocolates per minute (or 200
per lane). Subsequently, the products are wrappedand packaged.
Camas outstanding robotic know-how made it theright choice for the project. We were under a lotof pressure to deliver this project successfully inorder to meet the rapidly growing demand for ourproduct says Aleksey A. Klecov, OzerskyEngineering Manager. Cama was on our side andthe line was delivered within budget, on time andwith a successful vertical start-up.
CAMA USA Inc. 155 N. Pfingsten Rd. Ste#370 Deerfield, IL 60015Phone: 847-607-8797 - Fax: 847-607-8403 [email protected]
4. Focus on materials. Cartoning equipment isrelatively simple machinery; when there is a problem in
cartoning, usually its a material problem. Always remember
that the materials used or cartoning must be harmonized
with the machinery. Understand the material. For reliability,
make sure it is o good grade or quality. Is it virgin boardor recycled material? The answer has a signicant impact
on how the carton is handled. The design o faps and
glue patterns must be considered. You can use less glue
in a stitching pattern. When youre loading a bag into a
carton, the amount o air in the bag has a material impact.
You can use a defator on the ller or a conner on the
cartoner; either way, plan or this ahead o time rather than
discovering the need when the equipment is on the foor.Always test your products and materials at the equipment
vendor (see separate article on actory acceptance testing).
5. Match the equipment to your companystechnical capabilities. Cartoning equipment shouldmatch your companys technical prowess. Acquiring an
overly complex machine could prove problematic. Conduct
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End-of-Line Packaging Equipment Playbook
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continued
Eight tips or selecting
cartoning equipment
www.mgsmachine.com I 800.790.0627
Eliminate yourweb of suppliers
Nothing outsourced.Nothing overlooked.
Everything integrated.
Only MGS has a full range of
product handling equipmentintegrated into our secondary
packaging solutions
Scan here to
Reduce Your Riskon your next packagingequipment investment
a reerence check during your supplier investigation, and
talk to companies comparable to yours to determine i the
equipment you want is something that will per orm to
your specs and be manageable or you. Dierent cartoning
vendors do dierent things really well; make sure you
align their technology with your product, and know thelimitations o any piece o equipment youre thinking o
purchasing.
6. Look closely at the picking mechanism. Thisis oten overlooked. Look at the specic technology used
to pick carton blanks, and look its compatibility with your
particular substrate. I the machine doesnt pick your blank
correctly, nothing else matters.
7. Pay attention to operator ergonomicsand saety. How user-riendly are the controls and userinteraces? How ergonomic is the load/unload stations
where humans are involved?
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continued
Eight tips or selecting
cartoning equipment
For denesters,
onserters andhang tag applicators,pick our place.
InnovatIon. Its the name of our game.Our team of experienced design engineers can custom-designconventional and specialty equipment to do just aboutanything. Combine our innovative, sound designs with our24/7-customer support and the result is unmatched service,increased efciency and maximized production fromconcept to completion.
1-888-800-6861
www.graphicpkg.com
Watch demo
8. Dont orget parts. Have as ew change parts aspossible when you go rom one size to the next. (Obviously,
the ability to perorm quick changeovers is a key benet
when using many dierent carton sizes.) Standardizing
with components you already have is much more dicult
or end users than vendors realize (e.g., i youre used tohaving a certain kind o bearing and someone wants to use
a dierent kind o bearing, that can be painul). Keep parts
on hand to acilitate repairs.
9. Be aware o uture needs. Will you need largerpacks or multi-packs in the uture? I the machine only
goes between size A and size B, you may need dierent
equipment. Retrotting can be prohibitively costly. Plan orfexibility and change. Eventually you may need machines
or multiple geometries.
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Ten tips or buying coding/markingequipment or cases and pallets
The handling o case products hasnt changed, but the inormation required on the cases
has. This is driven by documentation concerns (i.e., traceability) and the growing realization
that all space is marketing space; so, cartons once considered dumb carriers are now being
leveraged to display corporate branding. Corrugated cases are moving closer to primary
packaging.
Also, ink-jet technology has improved considerably. Connectivity and ootprints are smaller
and machines are easier to use. There are common touch screen interaces, levels o
control, and higher resolutions. Instead o bottles o ink that you turn upside down, todays
technology eatures sel-sealing cartridges and meters or easy visual checks.
Here are some best practices to ollow and pitalls to avoid when buying coding/marking
technology or cases and pallets:
1. Understand your application ully to reduce costs. Its cheaper to use ink-jetthan it is to use a label, but will your application allow or it alone? Assess the technology in
detail in terms o what youre doing. Research the technical aspects o coding and marking to
ully understand the role o yield, imaging, and perormance to compare models and brands.
Learn how the equipment works; understand what dierent yield and imaging capacities
mean or your specic applications.
By MaRty weil
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2. Ensure that coding quality will meetcustomer needs. Large-character printers may not giveyou the highest quality scannable code. Companies such as
Walmart want better-quality coding on what they call high-
velocity goods, which they process in a highly automated
warehouse. For your product to qualiy as a high-velocitygood, you may nd that print-and-apply technology works
best, but at a higher total cost o ownership including
equipment and consumables (labels and ink).
3. Understand the impact o productdistribution. Rerigerated items will go through reezersand rerigerators. Be aware o where they sit at ambient
temperatures, where condensation is a risk. I the ink andglue on the label arent designed or your distribution cycle,
the label will likely be compromised and can even all o.
Your distribution process may move through dierent
environments, so consider how they will challenge the
packaging materials used.
continued
Ten tips or buying coding/marking
equipment or cases and pallets
High Resolution InkJet Printing
800-369-5384 www.foxjet.com youtube.com/itwfoxjet
Product Identifcation Solved!
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EQUIPMENT STRATEGIES
4. Assess impact o recycled content. Corrugatedcases come with increasingly higher recycled content,
which can impact label appearance, label adherence,
and printing. The higher the recycled content, the darker
the box, so with the higher amount o recycled content.
Sometimes it is necessary to print a light backgroundbeore applying a bar code to a case to obtain a unctional
contrast.
5. Closely track database activity. Databaseintegration ensures that coding on the cases ties into the
package itsel. Handling hasnt really changed, but the
inormation you want on the cases has. For example, the
Produce Traceability Initiative (PTI) is only a guideline; howyou implement it depends on your customer. I youre doing
barcodes, the most important thing is that you have a good,
scannable image. Know your customers, as they will drive
the standards youll have to meet.
continued
Ten tips or buying coding/marking
equipment or cases and pallets
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6. Be ready or changes. The packaging landscapeis increasingly fuid. Retailers such as Costco and Sams
Club are driving a trend toward shel-ready cases. More
companies are conscious that packaging space has
become a branding and messaging opportunity. Due to the
economic climate o the past ew years, anything to get themessage out rules. Cases o corrugated used to be generic;
in some instances, its moving closer to primary packaging.
7. Consider more than price. Besides cost, a hosto actors need to be considered beore buying coding and
marking equipment, including the equipments history
o use in applications similar to yours. Buying because a
system or machine is on clearance, or is the highest pricedso it must be the best, is shortsighted, as is thinking
that the mid-priced item is most sensible. Exercising due
diligence is essential to successul equipment specication.
Contact customer reerences who have purchased and use
the equipment in a similar setting to obtain eedback on
perormance and reliability.
continued
Ten tips or buying coding/marking
equipment or cases and palletsD-Series Laser Coders
Think small.
Everybody increasingly needs to do morewith less.
For the new D-Series scribing lasers, small
means more exible.
The new i-Tech scan head is beautifullycompact and ts where larger ones cannot.
The multi-position head makes it mucheasier to adapt to your production linefrom any angle, even in the most restricted
of spaces.
Modular construction includes an optionof standard or IP65 casings, and makes the
D-Series lasers footprint smaller overall.
Altogether a more compact industrial design(and 20% lighter) the new, smaller D-Seriesis a big improvement all round.
Domino. Do more.www.domino-na.com
1.800.486.7414
d f i k i i l b k
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8. Avoid generic equipment. Generic codingand marking equipment typically suits businesses with
very basic needs. Do you need more unique solutions or
customizable, robust unctionality? Opt or an equipment
provider that can grow and adapt as your companys vision
and objectives evolve in response to the market.
9. Dont orget maintenance and repair. Digdeep to ully understand the equipment reliability. Again,
reach out to current users o the equipment to gain insight
into daily maintenance as well as the foor perspective.Ask
about operating costs related to the lie o the machine in
terms o ink, maintenance requency, and the cost o repairs
and parts replacement. You may think the upront cost isthe biggest actor; however, the lietime costs can put a big
dent in the budget and aect the supply chain relative to
production schedules.
continued
Ten tips or buying coding/marking
equipment or cases and pallets
What does uninterruptedefciency look like to you?
The Videojet 2300 Series redefnes cost-efcient production.
These large character ink jet printers deliver consistent, high-resolution
variable data coding, eliminating the need or preprinted cartons
or labels. So you can maximize productivity and space-savings
while reducing inventory costs. The automatic micropurge o
the printhead ensures sharp image quality, case ater case,
even in dusty environments. The 2300 Series even recycles
ink used or the printheads micropurge to keep your ink drops
where you want it: on your packaging.
See or yoursel what uninterrupted efciency looks like.
Visit www.videojet.com/2300 or call 866-871-3226
Count on the Videojet 2300 Series of Case Coders to deliver it.
Ink Jet. Laser. Thermal Transer. Labelers. Track & Trace. Supplies. Parts & Service.
E d f Li P k i E i Pl b k
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10. Consider online case printing. Instead ohousing pallets o pre-printed cases, consider moving to
generic cases that can be printed online and labeled or any
SKU. This creates a tremendous reduction in inventory. The
print quality o digital and on-line case printing systems
have improved considerably, making this an option wellworth exploring.
continued
Ten tips or buying coding/marking
equipment or cases and pallets
I asked my box guyabout savings...
Iconotechthe only name
in Generic Case Printing
Saving money is no laughing matter. Printing
plates allow your corrugated supplier to hold you
hostage and all your purchasing power goes out
the window. Generic Case Printing and Iconotech
will give you back the control you need to succeed.
Buying more quantity of less generic inventory,
printing in-house and just-in-time can save you
hundreds of thousands of dollars annually.
Iconotech www. iconotech.com 800.521.0194
He laughed,
I called Iconotech
E d f Li P k i E i t Pl b k
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Trends in case packing equipment
There are a number o trends that are driving the design o modern case-packing equipment:
1. Retail-ready case packing. Originally driven by club stores, secondary packagingthat can be deployed right on the retail foor with attractive graphics and tear-away sections
or panels has probably been one o the biggest developments in secondary packaging in
recent years. The latest challenge is to be able to produce smaller-count cases at higher
speeds to maintain processing speeds. Also, using shel packages with visible product (suchas windows or exposed carton corners) requires automated machinery that minimizes surge
pressure during packaging. The kind o vacuum used to pick a case up really matters now.
Machines cannot mark, mar, or damage thecases in any way, because theyre being used as
displays now.
2. Lightweighting. Partly or sustainability reasons but also or cost savings, packagersare seeking to use thinner bags, thinner corrugated board, and thinner cartons. Machines
have been redesigned accordingly, handling product a lot more gingerly than they used to,
but still at high speeds.End-o-line packaging machines used to be typically xed-automation
machines. But now, to handle the prolieration o container shapes, sizes, and lighter weights,
whats required is more low-pressure conveyance, more customization, servos, and more
robotics. Robotics can be more ecient at handling lighter weight packaging because o the
amount o pressure and stress put on containers can be more tightly controlled. Pick-and-
place robots might be less likely to cause package damage versus more conventional xed-
automation and drop-pack systems.
By BRian kelly
E d f Li P k i E i t Pl b k
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3. Increased recycled content cases.Previously,case packers handled virgin corrugated board all the time.
As packers are now seeing a lot more recycled content, it
means that machines have had to be more orgiving and
provide or more tolerance o variation in the quality o the
cases and trays. Equipment really has to be less sensitive
and more tolerant, as variations are appearing on a more
requent basis. Recycled corrugated board also shows
more variation in how it reacts to the environment than
virgin board. Humid or cold environments add to the need
to build more tolerant machines. Vendors see this as an
opportunity to dierentiate, showing that they can handle
these variations. This leads to design changes, dierent
engineering, or reengineering: more use o high-strength,
lightweight materials in machines now, such as carbonber or end-o-arm tools, lighter-weight metals and other
advances in control and precision.
continued
Trends in case packing equipment
Weve got you covered, with quality,innovation, and service:
Proven performance
Reduced maintenance
Competitive pricing
On-time delivery
Expert installation
24/7 support, Factory parts
PMMI-certified trainers
Upgrade/refurbish service
For over 73 years, weve been helping our customersprofitably reach their production goals.
How may we help you?
www.abcpackaging.com
800-237-5975
811 Live Oak St., Tarpon Springs, FL 34689727-937-5144 - Fax: 727-938-1239
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4. Machines that accommodate packagingvariety. Marketing requirements are pushing the use oso many dierent packages that suppliers must be able to
deliver case packers that can, with just a ew change parts,
switly change over and accommodate the larger variety
o case sizes and ormats.The challenges are to convey,
accumulate, carton, case and/or wrap these packages at
high speeds, while keeping them well protected, and to be
able to rapidly changeover to dierent package types, pack
congurations, or various rainbow pack combinations
(or example, on-the-spot changeover o favor selections
in a multi-pack o beverage bottles). The increasing use
o servo technology is permitting this fexibility. Quicker
changeovers are driven by the desire to oer greater
customer choice to address occasion-based marketingthe right product in the right package at the right time and
place. Occasion-based marketing depends on the ability to
produce multiple packaging ormats or venues as diverse
as hotel chains, restaurants, club stores, and convenience
stores. Machinery users want to be able to run all these
diverse ormats on the same equipment.
continued
Trends in case packing equipmentS-T-R-E-T-C-Hyour adhesive
Dont let adhesive availability and risingprices slow you down. While otherslag behind, your packaging lines can
be running at faster speeds, using lessadhesive and saving you money.
Like the highway lines in the photo,youll replace long, continuous adhesivebeads with modulated intermittent beadsto optimize adhesive. You can save up to50 percent on adhesive while maintainingbonding and package integrity.
Avoid uncertainty and stay on the roadto success with OptiBond Solutions.
Call Nordson today at 800-683-2314 or
visit nordson.com/OptiBondSolutions
to learn more.
Get more mileage from your
adhesive. Let Nordson OptiBond
solutions help you spend more
time in the passing lane.
End of Line Packaging Equipment Playbook
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5. Adhesive advances. Manuacturers o adhesiveand adhesive applicator equipment have not stood idly
by either, introducing innovations such as non-heated
adhesive application systems that deliver a oamed
adhesive with rapid set properties. Advantages including
up to 50% less adhesive use than conventional systems,
room temperature pumping and fowing o adhesive that
eliminates the need or heated tanks and hoses, increasing
saety. Also, newer hot melt ast set adhesives are debuting,
eliminating the need or excessive heating and hot system
engineering, resulting in savings opportunities on wear
parts and maintenance because o the reduction in heated
components.
6. More integration. Packagers are pushing ormore integration in their lines; instead o buying discretepieces o machinery and cobbling them together, they
really are requiring that OEMs integrate complete end
o line solutions that achieve the desired output or the
continued
Trends in case packing equipment
End of Line Packaging Equipment Playbook
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End-of-Line Packaging Equipment Playbook
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entire line. Packagers want machines that can be able to
communicate with each other; theyre looking at the lines
holistically. They want the HMIs to have a similar look and
eel, more standardization o components, and theyre
speciying standardization o pumps and controls, and
are beginning to adopt PackML to streamline integration
between machines. A common platorm also makes it
easier or packagers to train their operators. In short,
whats driving case packing design is packagers need to
make the equipment easier to use, more accessible or less
experienced operators, simpler, aster changeover, and
greater fexibility because packaging styles change at an
unprecedented rate.
continued
Trends in case packing equipment
FOCKE & COGeneral PackagingIndustriestrae 1726676 Barel GermanyPhone: +49 4499 [email protected] www.focke.com
FOCKE & CONorth America5730 Millstream Rd.Whitsett NC 27377Phone: +1 336 [email protected] www.focke.com
TOMORROWSTECHNOLOGY TODAY
As one of the worlds leadingmanufacturers of packaging
machines, FOCKE & CO is aprivately held company with over16.000 installed machinesworldwide and more than 50years of experience.
Highly Flexible Packer ability to load mixed
orientations gentle product handling wide variety of product sizes
End of Line Packaging Equipment Playbook
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Checklist or buyingcase packing equipment
When you approach case packer manuacturers, its best to have a document prepared that
answers all o the ollowing questions:
1. Product and package. What is your product? What is the package type (e.g., carton,
tub, bottle, can, blister pack, etc.). Does this product have dierent sizes that you wanthandled on a single machine?
2. What are the dimensions o the primary package? Youll want to speciydiameter and height, i a round container. Or length, width and depth (LxWxD) i a carton.
Most case packer manuacturers will want LxWxD according to how the product will be
placed in the container relative to the container opening.
3. How will the product be delivered to the machine? Will the package bestanding up? Laying on its side? Entering the machine acing which way? Sometimes drawing
a little sketch showing how the package will be oriented on the ineed conveyor will help.
Also, what do you want to see when you open the case? How should the package printing or
labels be acing?
End-of-Line Packaging Equipment Playbook
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4. Line speed. How ast will containers be coming intothe case packer, in packages per minute?
5. Case count and pack pattern. How manyproduct packages will go into each size container? What
are your desired pack patterns? This can be communicatedby indicating the pack count along each dimension. For
example, 24-count 3x4x2 (LxWxD) means there are three
products along the longest fap (width dimension), 4
products along the shortest fap (width dimension), and 2
layers o product (stacked 2 high) in the depth dimension).
6. Weight/handling issues. Is your product very
heavy or very light? Wet, sticky, or slippery? Hard or sot?Hot, cold or rozen? Sturdy or wobbly? Liquid or solid? What
is the room temperature and humidity level where the
machine will run?
continued
Checklist or buying
case packing equipment
End-of-Line Packaging Equipment Playbook
http://www.packworld.com/playbook/forward/end-of-linehttp://www.accelacomm.com/jaw/source/67/50112540/http://www.hartness.com/http://www.accelacomm.com/jaw/source/67/50112540/http://www.packworld.com/playbook/forward/end-of-linehttp://prevpage/http://prevpage/ -
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7. What conguration are you looking or?Semi- or ully automatic? Wrap-around, horizontal, top or
bottom load? Let or right hand? Inline, perpendicular, or
counterfow? Glue (hot or cold) and/or tape sealing? Do
you have a controller preerence or special electrical or
automation standards?
This article was excerpted from a handbook from Schneider
Packaging Equipment Co., Inc.
continued
Checklist or buying
case packing equipment
We Provide
Complete
TurnkeyPackaging
Systems!
BluePrint Automation is a world leader in packaging automation. Ourmission is to deliver solutions that oer true fexibility in real worldproduction environments.
www.bpa-fexolutions.com
[email protected](804) 520-5400
Vision-Guided Robotics Case/Tray Packing
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Best practices or selectingcase packing equipment
Here are a ew things to look out or when selecting case packing equipment:
1. Know your product loading orientation.There are top loading, side loadingor end loading congurations available in case packing equipment.You can save a lot o
time and energy in selecting vendors and equipment i you know in advance just what theappropriate loading orientation is or your needs. Design in reliability. Ask yoursel i your
loading orientation can change to allow or enhanced reliability.
2. Look into how the case packer reacts to variances in materials. Tryto talk to other customers to nd out how the case packer responds when a lower quality,
damaged, or soggy (in humid conditions) piece o corrugated board is ed into it.
3. Ask other users about accessibility. When youre talking to customer reerences,ask whether their operators and technicians can you get into the machine to clean it. Is the
door accessible to the operators? Are guides and hold-downs too heavy to lit, or are they
ergonomic and user riendly? Can operators open and close the doors? Is it easy to replenish
the machine with blanks?
By BRian kelly
End-of-Line Packaging Equipment Playbook
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4. Dont ignore a machines ability andmethod or case squaring.The squareness othe case is critical or proper conveying and palletizing
downstream. As simple case squaring guides can also
cause the case to drag back and skew, consider positively
actuated case squaring. Accurate timing and positioncontrol are needed. A test with your actual appropriately
packaged product samples is best.
5. Find out what happens when you changesizes.Some packagers have to change a lot o sizes, andsome case packers require a lot o changes to do so. Is
the entire machine servo controlled? Is it all mechanical
adjustments? Are the size change controls and dialsaccessible and easy to operate? How oten will you be
changing over, now and in the uture? Customers are
demanding more customization, so be sure you select a
case packer that allows your operation to have the fexibility
to meet the uture demands o your customers.
continued
Best practices or selecting
case packing equipmentdeservegreat ideasgreat machines
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customers value with end-of-line automated systems
that redefine the standard. Our simple, clean, integrated
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Visit www.aagard.com and see how the Aagard
Advantage can become your advantage.
REDEFINING THE STANDARD
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6. Product control in case packing is o vitalimportance.The ability o a case packer to handle andmanage ineed pressure is key. You may be able to eed 100
eet o product, but i the case packer cant handle it, its bad
line design.Ater primary packaging, secondary packaging
can seem slow. Yet, incoming product speeds, linearspeeds, and cycle velocities are high. Avoid accepting low-
technology drives or actuators (air cylinders or example)
without closely evaluating whether the lack o velocity and
position control will cause eciency issues. A simple air
cylinder to tuck a case fap may seem adequate but as time
wears on, does it perorm the same or could its velocity and
motion change, causing jams? I a machine does jam, can
the actuator properly recover?
7. Re-consider case counts. Give thought to whatkind o case counts will work best or the case packer and
packaging line you are considering. For example, going
rom our cartons to ve cartons in a case will slow output
by 20%. That may be the dierence between running well
and not running well. Having said that, fexibilty in case
continued
Best practices or selecting
case packing equipment
Cooler is
cheaper.You can bank on the rst cool-on-delivery, hot-on-demand adhesive
system. Unlike hot melt with heated
tanks and hoses, Liquamelt means
less mess. Less energy. Less waste.
And less downtime. All of which,
adds up to more savings.
Learn more about how cooler is
cheaper at hbfuller.com/liquamelt
Adhesive System
2012 H.B. Fuller Company
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design necessitates a wide range o operational speeds.
Again, customer requirements or dierentiation in case
counts must be considered or the uture eectiveness o
your purchase.
8. Consider glue versus tape.Tape seals the caseagainst dust but does not necessarily hold the case square
during transporting (especially during palletizing, on
orklits, etc.). Glue seals aster and makes a stronger case.
Hot-melt seals very ast, needing little compression, but
costs more than cold glue or tape and typically needs more
maintenance. Cold glue has a superior bond with adequate
compression time (which typically means a longer machine
that costs more). Combination sealing can be used, such ashot/cold glue or glue/tape combinations.
continued
Best practices or selecting
case packing equipment
Cooler issmarter.Graduate to the rst cool-on-delivery,
hot-on-demand adhesive system.
Unlike hot melt with heated tanks
and hoses, Liquamelt isnt just
cooler. Its cleaner. Greener. Safer.
And cheaper. Making it a lot smarter.
Learn more about how cooler
is smarter at hbfuller.com/liquamelt
Adhesive System
2012 H.B. Fuller Company
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Wraparound versus RSC cases
It may be possible to save corrugated costs by switching to wraparound cases rom regular
slotted cases. To calculate potential savings, measure the length, width o each fap and panel
in your existing RSC, and sum the resulting gures. Include the manuacturers joint in your
measurements. Compare the totals or equivalent wraparound style case blanks. There may
be more waste with one wraparound case design than another, so less area alone does not
always mean a cost savings. To be sure, ask your corrugated manuacturer. The square ootage
o the corrugated can be less and the charge or gluing the manuacturers joint is eliminated.
Other benets o wraparound-style cases: A case magazine can hold twice as many
wraparound cases versus a standard RSC style. Also, the wraparound case is strong and oers
a tight product t which increases column strength and pallet eciencies.
Though a well-engineered case packer can be orgiving with badly made cases, its not worth
saving a ew pennies. Invest in quality cases or maximum uptime.
Tip: Ask your corrugated supplier to put a mark along one case old. This mark tells operators
whether a case is in the magazine upside down or backwards. Its a real time saver on a busy
production line.
This article was excerpted from a handbook from Schneider Packaging Equipment Co., Inc.
End-of-Line Packaging Equipment Playbook
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Glossary o case packing terms
Bottom Load Machine Product is loaded vertically up through the open faps on thebottom o a case.
Basis Weight Weight o various containers given in pounds per 1,000 sq. t.
Boxmakers Certicate Statement printed on a corrugated or solid breboard box
guaranteeing that all applicable construction requirements o the carriers have been met.Also identies the box maker.
CSO (Center Special Overlap Slotted Container) All faps are the same length;inner faps meet and outer faps overlap at random.
CSSC (Center Special Slotted Container) Inner and outer faps meet at center.
Containerboard The paperboard components (lineboard, corrugating material, llerchip) where corrugated and solid breboard is manuactured.
Corrugated Board Board consisting o two outer plies that sandwich a futed middle layer.
Cycle Process by which product package or container moves rom station to station inaccumulator or main machine. (see Station or Pockets)
This glossary was adapted
rom a handbook by
Schneider Packaging Equipment.
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continued
Glossary o case packing terms
Double Wall A combination o three fat acings andtwo intermediate corrugated parts.
Enclosure Types Electrical connection protectionlevel or the operating environment (see the basic NEMA
ratings page 39):
Facings A orm o linerboard used as fat members ocorrugated breboard.
Fibre or Fibreboard Box A container madeo either corrugated or solid breboard; breboard is
abricated paperboard (three or more plies o walls).
Flute or Corrugation One o the wave shapes in the
inner part o combined corrugated breboard.
Flutes perlinear oot
Approximate height(not including acing thickness)
A-fute 33+3 3/16 inch
B-fute 47+3 3/32 inch
C-fute 39+ 9/64 inch
E-fute 90+4 3/64 inch
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continued
Glossary o case packing terms
FOL (Full overlap Slotted Container) All fapssame length; outer faps overlap not less than inside width
o box minus a maximum o one inch.
Hal-Slotted Case An RSC style with bottom faps andno top faps.
Hand, machine Let-hand machine meansaccumulator is on let side o main machine when looking
in the fow direction and conveyor is on right side o main
machine discharge.
Horizontal machine Product is loaded (horizontallypushed) into the side or end o a carton, case or tray.
Inline machine Main machine is placed lengthwise inthe same direction as the conveyor delivering product.
Knocked-Down (KD) A term denoting that a carton,case, or tray is partly or entirely taken apart; not setup.
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continued
Glossary o case packing terms
Liner (Sleeve) A creased breboard sheet inserted in acontainer and covering all side walls.
Manuacturers Joint The joint is that part o thebox where the ends o the scored and slotted blank are
joined by tapping, stitching, or gluing. When nished in the
box manuacturers plant, it is known as a manuacturers
joint; when the box faps are sealed in a box users plant
(usually on automatic equipment), it is called a users joint.
NEMA Ratings Rating scale or measuring the level oprotection or electrical connections given the operating
environment.
NEMA 1 General purpose; indoor usage; no unusualservice conditions.
NEMA 2 Dripproo; indoor usage; protect against non-corrosive liquids and dirt.
NEMA 3/3R Dustlight; raintight and sleet (ice) resistant;outdoor usage; protects against windblown dust and water.
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NEMA 4 Watertight and dusttight; indoor and outdoor usage; protects against splashingwater, water seepage, alling or hose-directed water, severe external condensation.
NEMA 4X Watertight, dusttight, and corrosion resistant; indoor and outdoor usage; seeNEMA 4 above plus corrosion protection.
NEMA 7/9 Explosion resistant; indoor hazardous locations; airbreak equipment to protectagainst entrance o explosive amounts o hazardous dust.
NEMA 12 Dusttight and driptight; indoor industrial usage; protects against bres, lings,lint, dust, dirt, light splashing or seepage, dripping and external condensation o noncorrosiveliquids.
NEMA 13 Oiltight and dusttight; indoor usage; houses limit switches, oot switches,pushbuttons, selector switches, pilot lights, etc. to protect against lint, dust, seepage, external
condensation, spraying o water, oil or coolant.
Orientation How a product is delivered to an ineed conveyor, discharge conveyor, orloaded into a containere.g. largest dimension perpendicular or parallel to fow; largest
dimension perpendicular or parallel to case length, width, or depth. Product length, width,
and depth are relative to how it loads into the case.
continued
Glossary o case
packing terms
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Overlaps A design eature where the top and/orbottom faps (usually outer only) extend over the other.
Overlap is measured rom fap edge to fap edge and is
known as partial or ull overlapping faps.
Pocket Space reserved in main machine to do one o
the ollowing operations case select, case erect, case old,
case load, case fap tuck, case seal, case seal compress.
Some o these operations can be done in the same
horizontal space under certain conditions (slow speed,
small product, smaller ootprint needed). Product is passed
rom one pocket to another by pushers.
RSC (Regular Slotted Container) All faps samelength; outer faps meet.
Single Face A combination o one corrugated partglued to one fat acing.
continued
Glossary o case packing terms
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Single Wall Also known as Double Face. A combinationo one corrugated inner part glued between two fat acings.
Standard Test Conditions Tests on paperboardand boxes are normally done at 73 degrees F and 50% RH +
or 2.5%; High humidity is temperatures above 73 degrees F at
85% RH; Cold storage is below 40 degrees F at 85% RH; Tropical
storage is above 90% degrees F at 90% RH.
Station Divisions within the main machine thatmechanically perorm unctions necessary to erect, old,
load, tuck, glue or tape, and seal a container. These stations
can be combined under certain circumstances into multi
purpose units. (see Pockets)
Test Bursting strength o linerboard and combined boardexcept or those grades o corrugated breboard where a
puncture test is substituted or bursting strength. There are
many kinds o tests done depending on environment.
continued
Glossary o case packing terms
Pegasus Cartonercarton/collate/casepack
Cartoners, Trayformers, Casepackers.and
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Automatic or manual loading
Glue, Tuck, or Tape Closure
Paperboard or Corrugated Cardboard
Simple, Flexible, Compact Design
PMMI Certified Service and Support
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Nine tips or selecting multipackingand shrink bundling equipment
In todays multipacking and shrink bundling environment, the need or fexibility and
precisely repeatable changeovers is taking precedence. This is driving equipment design,
even on highly complex equipment. It is also infuencing the dumbing down o machines,
specic to changeover and fexibility, where responsibility is taken out o the hands o
operators, or removed entirely. Users are demanding higher overall equipment eectiveness(OEE), longer mean time to ailures, and greater predictability.
Machine builders are adding control with ully integrated robotics instead o integrating with
another machine or added unctionality. Rather than having three axes o linear movement
(e.g., a pusher), the vendor may install a delta or Cartesian robot. Robots are simpler and
cheaper than they used to be, and utilize smaller ootprints.
The prolieration o SKUs and brands has driven down shel space, which in turn has increasedinventory turns and the desire or smaller packages. This need has dramatically increased
bundling speed. The costs o bundling, labeling, and coding have almost doubled due to
sending the same tonnage in smaller bundles!
By MaRty weil
45 / 100
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Here are some tips to consider or those selecting
equipment in this challenging environment:
1. Look to downgauge.The use o polyethyleneand similar thin lms is a huge cost-cutting opportunity.
Fity percent o customers use heavier gauge lm than
they need. Why? A thicker gauge buys a lot o orgiveness,
allowing companies to get away with sloppier setup, less
ecient machines, and less competent operators. Premium
lms are being used to accommodate these shortcomings.
While downgauging involves a lot o work, it can pay o.
Instead o using a lm that costs $4 a pound, you can
use one that costs $0.71 a pound with the right bundling
machine. In act, lm suppliers are producing better-quality,inexpensive thin lms.
2. Identiy the right technology platorm,especially i its a new process or thebusiness. Whether its a wraparound tray, corrugatedpad, or unsupported shrink bundle see what your product
and distribution environment can handle. Rigid containers
continued
Nine tips or selecting multi-packing
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F O R M I N G L O A D I N G C L O S I N G 800-328-5558 delkorsystems.com
packaging innovation at work.T
ATYOUR COMMAND
CASE PACKING WITH RETAIL READY
Delkors Case Packing solutions provide unique fexibility.With todays rapidly changing retail environment one cannot afford to havea packaging line that only produces one package style. A Delkor case packeris designed with the versatility to run a variety of package formats, includingRetail Ready . . . all with tool-less changeover.
We engineer our machines to protect your investment.
To see it in action, visitdelkorsystems.com/retail-ready-packaging.html
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EQUIPMENT STRATEGIES
such as metal cans easily transition rom a tray to a pad. But
what i youre dealing with a 3-ounce plastic bottle with an
hourglass shape? Be very careul and do a lot o testing to
see i its even possible to move rom a tray to a pad to an
overwrap. Shrink-only packs will obviously save corrugated
costs, but such a move requires oresight and planning
to ensure package integrity with package development
experts.
3. Speed matters.The speed at which youre packingor bundling is a key parameter. The number o products
on a pad or shrink bundled remains on the upside o the
growth curve. Consider this as you examine potential
equipment. While there are no hard and ast rules, theimpact o product development on bundling speed cannot
be ignored.
4. Size matters as well. Pay attention to the lengtho the shrink tunnel. Dont undersize it. Film takes a certain
amount o time to heat up and shrink. Selecting shorter
heat tunnels with higher heats is not good logic. For higher
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Nine tips or selecting multi-packing
and shrink bundling equipment
The EM series o machines rom Optima Machinery Corporation are
designed as ully automatic, in-line, robust systems. The EM utilizes
an integrated stacking unit to create side-by-side, double, or quad
ormations. The EM oers the unique capability to automatically pull
the required flm to match the circumerence o the bundle. Thereo-
re, making it possible to run and create side-by-side, double, or quad
bundles sequentially.
Grouping and
Bundling.
EXCELLENCE IN PACKAGING
OPTIMA
20 Product/ min. Input 5-10 Bundles/ min. Output
OPTIMA Machinery Corporation | 1330 Contract Drive | Green Bay | WI 54304-0173 | USA
Phone +1 920 339-2222 | Fax +1 920 339-2233 | E-Mail [email protected] | www.optima-usa.com
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