PACK EXPO 2018 review: equipment innovations and industry trends
PACK EXPO recently took place at McCormick Place, Chicago, from October 14-17. IFT is presented by PMMI.
3M
3M introduced its Scotch High Tack Box Sealing Tape 371+, which provides a tamper-evident seal with the highest strength and durability in tough environments. Boxes will stay closed throughout the supply chain no matter the percentage of recycled content—even in cold temperatures. Scotch High Tack Box Sealing Tape 371+ is ideal for food and beverage, electronics and e-fullfillment industries.
A-B-C Packaging Machine Corp.
A-B-C Packaging Machine Corp. introduced end-of line case erecting and sealing, palletizing, and depalletizing equipment at their booth. Their bulk depalletizers automate the line, reducing labor and liability. For plants with either limited floor space or a small budget, their compact palletizer (Model 72AN) offers a simple and economical solution to increase production and eliminate the cost and liability of manual operation. It occupies from 10 to 30 percent less floor space than conventional low level palletizers depending on the accessories required (transfer conveyor, pallet dispenser/transport) and offers complete flexibility for product feed and pallet configuration. All operation is automatic which eliminates the risk of employee injury and related costs from repetitive palletizing actions.
Bosch Packaging Technology
Bosch Packaging Technology discussed three new machines: the new Pack 102 entry-level stainless-steel horizontal flow wrapper, the new Pack 202 mid-speed flow wrapper and the new Kliklok Midrange Endload Cartoner (MEC). The Pack 102 is suitable for start-ups who are taking their first steps in automation. The Pack 202 is ideal for mid-speed, multi-product applications and was shown in a complete packaging system with a stainless-steel Paloma D3 robot and a Kliklok ITC topload cartoner. The Kliklok MEC features a sanitary design, tool-less changeover and easy operator access. It packs up to 170 cartons per minute and is designed for the highest food safety standards and for maximum production levels. The company also demonstrated a new virtual reality planning tool that transforms two-dimensional sketches into three-dimensional images of the planned packaging system. This allows the customers to visualize how much space is needed to fit in all the machines, how the operators will access specific parts of the production line and where the bottlenecks are. Guests at the booth also experienced how virtual reality can help in off-site operator training.
Constantia Flexibles
Constantia Flexibles has developed a new, more sustainable packaging line named Ecolutions, which made its debut at PACK EXPO 2018 in Chicago. Ecolutions meets sustainable requirements, reduces the carbon footprint of packaging, focuses on recyclable solutions and decreases the impact on the environment. The Mono PE laminate EcoLam is lightweight and its OPE/PE structure is fully recycle-ready due to its mono-material structure. In addition, its carbon footprint is approximately 32 percent smaller than that of comparable products. Another advantage of the EcoLam packaging line are the great barrier properties. Constantia Flexible also discussed Constantia Interactive, which turns your package into a content channel. Shoppers can scan the packaging via a smart device’s camera and experience a wide variety of consumer engagement features. Real time data tracking helps manufacturers understand consumer behavior and enables direct online marketing.
Dorner
Dorner’s newly redesigned AquaGard 7350 V2 Series is engineered for industry standards. The AquaGard 7350 V2 is built for numerous sanitary applications within baking, snack food, and other industries that require occasional wipe-down cleanings of the conveyor. The new conveyor comes in straight belt, as well as modular belt straight and curve models. Belted LPZ, modular belt LPZ and positive drive models will be available in the coming months.
Eagle Product Inspection
Eagle Product Inspection introduced its new EPX100 X-ray inspection system at PACK EXPO, a safe, simple and smart x-ray inspection system ideal for small to medium-sized packaged products. Its low energy design reduces operating costs and delivers exceptional contaminant detection performance. It also has an improved algorithm, and a greener footprint. The EPX100 is ideal for inspecting cartons, pouches, plastic containers and items wrapped in foil or metalized film. It can detect contaminants such as metal, glass, mineral stone, calcified bone and many high density plastics.
Epson Robots
The new Epson robot offers the perfect way to automate factories without wasting time or money on expensive, complex, slide-based solutions. Available at the low price of $9,495, this innovative alternative installs in minutes and virtually eliminates any space-constraint issues. The T6 is ideal for simple applications such as pick and place, assembly, parts handling and dispensing applications.
Eriez
Eriez introduced its new and improved Xtreme Vertical Form, Fill & Seal (VFS) Metal Detector. This compact unit requires no metal-free area above or below the sensing head, making it ideal for installation in the space-restricted area before the hopper and forming tube. Eriez’ Xtreme VFS Metal Detectors meet stringent standards for food processing environments and offer the superior sensitivity customers expect from Eriez. These units, suitable for washdown, detect millimeter-sized metal spheres and feature food grade pipe and stainless steel construction. Xtreme VFS Metal Detectors are available in 3-inch, 4-inch, 6-inch, 8-inch and 10-inch aperture sizes to meet practically any application need. Total installation height requirements vary from 9.75 inches to 12.75 inches, based on aperture size.
FANUC America
FANUC America demonstrated its expanded line of collaborative robots including the new CR-15iA. The six-axis CR-15iA is FANUC’s latest in a series of collaborative robots that offer payloads from 4–35 kg. The CR-15iA features a built-in sensor that allows it to work safely alongside people in a variety of jobs. FANUC’s expanded line of collaborative robots can perform more strenuous or repetitive tasks without the need for expensive industrial safety barriers. The CR-15iA offers a 15 kg payload and 1,441 mm reach, providing a mid-range option. All of FANUC’s power and force limiting collaborative robots are green to distinguish them from the standard yellow FANUC robots. The CR-15iA was used to demonstrate pick and place and palletizing/de-palletizing tasks, both using hand guidance.
Fortress Technology
To maximize the probability of detecting metal contaminants in high value foods, in particular confectionery and low-side profile products, Fortress Technology unveiled what is believed to be the first ever multi-orientation, multi-scan food metal detector. Named the Interceptor DF (Divergent Field), the system can be customized to different aperture sizes depending on the products being inspected, and offers detection performance levels that outperform any current technology, including X-ray. It is especially sensitive to very thin contaminants that are difficult to detect and can be missed by other technologies.
Fresh-Lock by Presto
Fresh-Lock by Presto celebrated its 30th anniversary at PACK EXPO 2018 with a special booth design, new equipment and the latest in packaging and closures. Further demonstrating its dedication to the future of flexible packaging, the Fresh-Lock PACK EXPO booth featured a unique design showcasing the personas that are currently driving consumer trends and the industries impacted by the latest innovations in closures. Show attendees were able to experience Fresh-Lock’s newest products and developments as interactive displays came to life and offered key industry insights.
GEA
GEA introduced its new GEA SmartPacker CX250-S, which can pack at rates up to 250 bags per minute. It has high seal pressure, allowing for gas-tight packs using a wide range of film material, a low drop height for fast, compact filling, and a high output per square foot of floor space. Its features were designed with automation and high speeds in mind, and its simple open design does not require much maintenance. The SmartPacker CX250-S would be perfectly suited for 100-calorie snack packs, offering high-speed/high-capacity production.
Goodway Technologies
Goodway Technologies has released the Portable Jet System 4 dry steam belt cleaner. The Jet System, which has a touchscreen display, makes it easier to maintain open mesh belts by allowing dry steam cleaning to take place without removing the belt. It’s suited to use in areas where wet cleaning needs to be avoided, such as bakery, snack and confectionary production environments. Producing as little as five-percent moisture content, with no wastewater generated, the dry vapor steam leaves surfaces clean, dry and ready for final sanitation with a product like the BioSpray-20 surface sanitation system.
Harpak-ULMA
Harpak-ULMA introduced a new smart manufacturing initiative to improve total cost of ownership for packaging solutions—from smart connected machines to AR. They recently announced that they joined the Rockwell Automation PartnerNetwork program as an OEM Machine Builder. As a member of the PartnerNetwork, Harpak-ULMA is teaming with Rockwell Automation, Inc. to facilitate the development of smart, connected packaging solutions. The company’s ULMA Thermoformer lines are now delivered with the Integrated Architecture production control and information system from Rockwell Automation, and can leverage IoT and augmented reality platforms supplied by smart manufacturing software leader PTC.
Honeywell Intelligrated
Honeywell Intelligrated showcased its connected solutions for automated palletizing equipment in end-of-line manufacturing environments. By leveraging data from machine-level sensors, the company provides real-time equipment monitoring, diagnostics and asset-level insights to boost reliability, throughput and performance. These connected solutions analyze real-time and historic data to detect equipment conditions that could impact performance—such as excess motor vibration, temperature fluctuations or underutilization trends—and provide real-time alerts to help fix critical issues before they affect the entire production process. The booth demonstration featured the Alvey 890i palletizer, capable of handling a variety of stacking patterns, small and difficult-to-handle products, and a wide range of packaging types.
JLS Automation
JLS Automation demonstrated automated loading of fresh bread into gas-flushed packages to extend the shelf life of these higher-end products. The new system for modified-atmosphere packaged fresh bread comprises the company’s Talon robotic pick-and-place system and a new robotic end-of-arm-tool. Together, the system loads full, sliced loaves into a thermoformer for MAP packaging. A conveyor with special guides ensures the sliced loaves are handled gently and presented to the Talon efficiently and intact.
Lantech
Lantech demonstrated its new QL-400XT Semi-Automatic Stretch Wrapper, the first intuitive, intelligent and instructional semi-automatic stretch wrapper that allows safe-to-ship wrap profiles to be built, quickly and easily, for any load configuration. The QL-400XT’s intelligent wrap control guides operators through the profile setup process with smartphone-like simplicity. The QL-400XT improves productivity by allowing operators to stay on the forklift. Also on display was the new CI-1000 In-Line Case Erector, a versatile and easily integrated case erector. At 1 meter wide, it’s a good solution for manufacturers that need multiple packaging lines in facilities where space is tight. An easy-to-load “walk-in” magazine simplifies size adjustments, and machine settings can be adjusted within seconds. The company also showed its new RL Automatic Stretch Wrapper, its next generation of ring technology. The RL Automatic Stretch Wrapper maintains high-speed ring rotation without compromising cost or load technology while minimizing operator touches and costly machine downtime.
METTLER TOLEDO
The new METTLER TOLEDO CX35 Combichecker is the latest in the company’s line of product inspection systems integrating checkweighers with other inspection systems. Following its introduction in recent years of combicheckers combining checkweighing with metal detection and machine vision inspection, the CX35 links METTLER TOLEDO’s highly precise and versatile C35 checkweigher with its advanced X33 X-ray inspection system.
PMI KYOTO
PMI KYOTO exhibited its new Tri-Seal Top-Load Cartoner. The new machine integrates a pick-and-place delta robot to achieve consistent, accurate product fills at higher speeds with less downtime. The cartoner can accommodate a second delta robot at the machine infeed to fill up to 60 cartons per minute. End-of-arm tooling, buckets and containers can be changed to carton flow-wrapped, bagged and thermoformed packages. A re-orientation turret rotates product 90-degrees, or up to 180-degrees, to align with the orientation of the conveyor for maximum efficiency. Unlike traditional cartoners where a mandrel presses a sheet down to form a carton, the Tri-Seal Top-Load Cartoner places a sheet between the carton former and vacuum belt, and the carton former acts as the mandrel as it travels up to press against the form. Because the sheet is controlled the entire time, it creates more-accurate, higher-quality cartons.
R.A Jones
R.A Jones, in partnership with VOLPAK America and FLEXLINK Systems, debuted an integrated pouch/cartoning line. The line featured the enhanced VOLPAK SI-280 HFFS pouch machine, a new intermittent motion cartoner from R.A Jones, the Criterion CLI-100 (latest addition to the Criterion family of cartoners), and FLEXLINK’s RC10 palletizing robot. All were connected with FLEXLINK’s premium conveying systems, making it a single source solution. The new intermittent motion Criterion CLI-100 builds on the success of the recently launched Criterion CL-240, engineered to provide more flexibility for running different types of products and the largest range of carton sizes in the industry.
Rockwell Automation
Rockwell Automation discussed several topics: Smart Flexible Manufacturing, to show how companies are leveraging innovative technologies to add more flexibility into manufacturing; Advanced Technology in Life Sciences, covering how business models in life science manufacturing are evolving to support changing market demands; Analytics for Delivering Business Value in Industrial IoT, illustrating how big data will become less relevant in the future and increasingly be replaced with contextualized data and digital twins that are embedded in devices, machines and the cloud; and Cybersecurity in Manufacturing Operations, with recommendations on best practices and actionable steps industrial companies can take with reference to network security and standards within the industry.
Sappi
Sappi North America debuted its first two new premiere boards, Proto and Spectro, at Pack Expo 2018. This product launch comes on the heels of a year-long rebuild of Sappi's Paper Machine 1 and modernization of the woodyard both at its Somerset Mill in Skowhegan, Maine. Together, Sappi invested over $200 million in these two projects. Proto is a sturdy, single-ply SBS capable of meeting a breadth of applications from general folding carton and food packaging to pharmaceutical and OTC. It's the paperboard for everyday jobs, providing an unmatched yield advantage, and superior surface and printability for a lasting impact. Spectro is a single-ply SBS with enhanced optics, making it ideal for premium applications that call for dynamic and vibrant images. Whether using UV, aqueous, or specialty coatings, hot foil stamping, embossing, special effects, or varnishes, Spectro has the surface for the most demanding applications.
Schubert
Schubert presented the advanced features of its Flowmodul flow-wrapping component. Thanks to new heat-sealing technology, heat-sensitive products can now be packaged gently in flow-wrap bags. The machine’s robot tools are precisely adapted to product-specific applications, contributing to the flexibility of the TLM machines. The latest Flowmodul flow-wrapping component features an open machine layout, providing easy accessibility for maintenance and cleaning. Schubert now offers an even more-extensive selection of possible sealing technologies. All TLM machines can be connected with the GRIPS.world digital platform via the internet. Through predictive maintenance, this platform ensures long-term investment security in a TLM system. In the future, customers will benefit from the integrated condition monitoring of information and data to boost productivity.
Shuttleworth
Shuttleworth, part of the ProMach family of brands, demonstrated its new high-speed Laner, an innovative, high-speed solution for dividing product from single to multiple lanes, mass-fill ovens, freezers or any other equipment requiring spreading or dividing of product. Combined with the company’s Slip-Torque conveyor surface design, continuous motion dividing allows speeds of up to 600–700 products per minute for small to medium-sized products. This laning device is designed with all mechanisms under the conveyor surface with nothing over the product, making it an extremely sanitary design. Automatic setups provide customers with a quick, easy, seamless process for product changeovers.
SICK
SICK presented its own smart factory featuring sensor intelligence—programmable and self-learning cameras, reliable safety sensors for human-robot collaboration, and complete solutions for navigating autonomous guided vehicles. All these devices are connected with one another via the cloud. Decentralized intelligence in the sensors forms the basis for flexible control of production processes in the smart factory. Additional cloud intelligence in the form of data analyses and applications allow the use of self-learning mechanisms in the sensors, increasing their adaptability to production-related changes. The supply chain is taken over by driverless transport systems together with collision prevention solutions. The data from all the sensors in the smart factory are evaluated on a large display giving visitors a constant overview of logistical and production processes, as well as key performance indicators.
Siemens
Siemens discussed the power of the digital enterprise. Visitors to the booth learned how digitalization can increase productivity, flexibility and reliability. Topics at the booth included digital twins—a precise virtual model of a product or a production plant—for product, production and performance to reduce time to market; totally integrated automation (TIA), used to activate the full potential of production with a digitally enriched automation portfolio to continuously optimize and improve plants and machinery; motion-control solutions for individualized mass production; and MindSphere, an open, cloud-based IoT operating system.
Soft Robotics
Soft Robotics demonstrated the advanced capabilities of robotic grasping technology that enables the handling of variable, unstructured tasks without the need for complex programming or sensors. This solution provides manufacturers with the flexibility to automate processes that were otherwise incapable of being automated. A fully-automated grocery order fulfillment system enabled by the SuperPick system was demonstrated in the booth. Designed specifically for e-commerce, grocery, retail and logistics environments, SuperPick combines Soft Robotics technology with artificial intelligence to enable the automation of highly unstructured tasks like bin picking and sorting. Soft Robotics’ gripping systems are designed to mimic the dexterity of the human hand and can grasp items of various sizes, shapes and weight with the same easy-to-use end of arm tool while keeping the integrity of the handled product intact.
Somic America
Somic America demonstrated the SOMIC-FLEXX III, a modular machine that combines the ability to pack primary packages in a flat, nested position or a standing display orientation. The machine also is designed to utilize single or multi-component packaging: one-piece corrugated blanks for standard wraparound shipping cases, and a two-piece tray and hood for retail-ready presentations. It does so by offering the utmost in adaptability and impressive speed, along with the latest generation of industrial automation from Rockwell Automation and UL-certified components.
Stäubli
Stäubli demonstrated its industrial robot TX90 HE, which was developed especially for applications in humid environment. It does not require a protective cover. It offers an articulated arm for extraordinary dexterity and flexibility thanks to its 6 axis design. The compactness of the arm and the large work envelope allow maximum utilization of cell workspace. The integration of the robot on the production line is made easier thanks to multiple attachment methods, floor, wall or ceiling. It’s compatible with most commonly used cleaning solutions for full washdown.
Thermo Fisher Scientific
The Thermo Scientific Sentinel 5000 Multiscan Metal Detector features an advanced multi-frequency metal detection technology platform called multiscan, designed to provide improved sensitivity and increased probability of detection of metal foreign objects in food. Multiscan uses five simultaneous frequencies to detect contaminants up to 50 percent smaller in volume than previous technology. It is the equivalent of running five metal detectors in a row, all scanning for different metal contaminants. To learn more about how the Sentinel 5000 and multiscan technology can support food safety and quality goals, visit www.thermofisher.com/Sentinel5000.
TNA North America
TNA North America has introduced the tna intelli-sys iPS 3, a fully integrated, high-performance data collection and reporting tool to provide manufacturers with insights into all their production processes. With the software, food manufacturers will be able to use a single, standardized platform to collate, visualize and evaluate live and historical information from every part of the production chain and across multiple locations. By integrating data from every process and at every site in a single-plant management system, the tna intelli-sys iPS 3 increases visibility, reduces administrative tasks, optimizes processes and improves traceability, resulting in a smarter, more-transparent and ultimately more-profitable manufacturing process. Compatible with both PLC and PC-based technology, the system integrates with all existing tna and third-party equipment. Thanks to the system’s real-time data acquisition capabilities, faults are detected much more quickly than humanly possible, ensuring downtime and waste are kept to a minimum, while food safety and product quality are maintained at all times. The collation of detailed historical data, such as batch scheduling, tracking and tracing, can be used for both internal communication purposes, but also as an external tool to prove regulatory compliance.
Toshiba
Toshiba America Business Solutions spotlighted its print and apply product during PACK EXPO 2018. The system—demonstrated throughout the event in booth E-10717—coupled Toshiba’s thermal barcode printer technology with Panther Industries’ automated labeling product. The solution integrates with automated shipping systems such as conveyors, scanners and warehouse management systems to streamline labeling.
VAC-U-MAX
VAC-U-MAX Signature Series offers food processors a quick and easy solution for vacuum conveying powders, pellets, flakes, pastilles, dried fruit, nuts and many other granular food ingredients to processing and packaging lines. Sanitary systems are available in 1500 Series for conveying rates from handfuls to 1500 lbs/hr (680 kg/hr) or 3500 Series for conveying rates up to 3500 lbs/hr (1600 kg/hr)—with systems available for higher rate applications. Each 5-part “plug-and-play” system includes a pick-up wand, convey hose, VAC-U-MAX Signature Series Vacuum Receiver with automatic pulse filter cleaning, a vacuum producer, and UL-listed controls. Typical applications include source to destination conveying from totes, drums, bulk bags, bag dump stations and more—to feeders, mixers, blenders, screeners, extruders, auger filling and/or packaging machines.
Van der Graaf
Van der Graaf discussed its IntelliDrive drum motor with an integrated VFD that is Ethernet/IP and MODBUS compatible and enables communication with other plant equipment. It provides conveyor drive data feedback and controls belt speed either remotely or directly at the drum motor. Lab test results of the IntelliDrive show electrical savings of up to 72 percent without loss of torque or belt-pull compared to a conventional motor/gearbox conveyor drive.
Yale Materials Handling Corp.
In an age of increasing demand and limited workforce availability, operations are turning to robotic solutions to optimize workflow and enhance labor efficiency. Yale Materials Handling Corp. highlighted the latest addition to its robotic lift truck lineup, the Yale MC10-15 counterbalanced stacker Driven by Balyo. The counterbalanced stacker model is capable of point-to-point horizontal transportation, as well as vertical movement, allowing it to autonomously retrieve or deposit pallets from elevated spaces. This opens a variety of tasks for automation, including transferring pallets from floor-level staging areas to conveyor lines, loading and unloading in cross-docking applications, and stacking pallet loads onto elevated storage racks. Personnel can switch the CB stacker from automatic to manual mode at the touch of a button, enabling them to handle unplanned challenges or fluctuating demands.
Yaskawa Motoman
Recently introduced by Yaskawa Motoman, the powerful and efficient GP-series robots are now available with payload capacities from 7 kg to 600 kg and are designed for a wide range of handling applications. The compact six-axis GP7 robot demonstrated a fast-paced palletizing application. Select GP series robots, including the GP7, GP8 and GP12 models, can be programmed with the new easy-to-use touchscreen Smart Pendant, which features intuitive controls and patented Smart Frame technology, which eliminates the use of coordinate frames and allows for simplified robot jogging. GP series handling robots are available in a wide range of payload and reach capacities to meet nearly every demand.
Zip-Pak
Safety-Lok is the new child-resistant slider zipper from Zip-Pak: a simple, intuitive one-step opening mechanism providing deterrence for children, yet easy access for the intended consumer. Safety-Lok Child Resistant Slider utilizes Zip-Pak slider technology, creating a cost-effective solution designed to keep children safe from harmful products. The key differentiator of Safety-Lok Child Resistant Slider is the proprietary clip mechanism allowing the package to be opened from any position with a light squeeze, creating a wide-mouth opening for easy access to package contents.