27 March 2020

Preventing machine downtimes in end-of-line packaging

Body: 

To what extent can a case packer contribute to avoiding production stops caused by an anomaly or an overload in upstream machinery?
Let's try to answer this question, trying to identify the causes leading to downtimes, but, most importantly, the factors that can contribute to preventing or avoiding them.

 

CASE PACKER BUILD QUALITIES

Let's begin by saying that downtimes caused by end-of-line packaging machines are rare. This is mainly because these machines are robust and "less" complex than a bottling or a food filling machine.

Furthermore, downstream machines are usually oversized, in order to handle overloads and ensure production continuity.

To guarantee maximum line efficiency, case packers must come with high standards in terms of:

Hardware – both with regard to design and selection of best brand components

Software – Touch screen and pre-installed sensors programmes have to be stable and well structured.

Artema Pack also strongly believes in customising performance, meaning that both the machine and the software must allow for a "tailored" configuration, according to the processes and specific features of the production line.

 

THE ROLE OF MAINTENANCE

Artema Pack machines are built to be "tanks": indestructible, unstoppable and always ready to fight.

Actually, we have been trying to further reduce maintenance services by introducing, for example, automatic chain lubrication.

Nevertheless, standard maintenance must be carried out regularly, in order to ensure the case packer's proper functioning and performance over time.

As per user manual, the following operations must be carried out on a regular basis:

  • Cleaning – die cut cartons release dust and residues that could damage machine efficiency over time
  • Components check – periodically checking suction cups and mechanical parts for indications of wear.
 

PROPER STORAGE OF BLANK SHEETS

Faulty die cut cartons - though rare - cannot be foreseen; therefore, an accurate visual inspection must occur before magazine loading.

In order to prevent downtimes due to carton jamming, blanks must be stored and handled correctly:

  • Die cut carton boxes in the magazine shouldn't be too heavy
  • Cartons must never come into contact with humidity
  • (even slightly) damaged sheets must be discarded

 

THE IMPORTANCE OF TRAINING

The goal of our post-installation training is to enable operators to handle daily operations and the standard maintenance of end-of-line packers autonomously.

In particular, Artema Pack tries to convey a working method for the whole packaging process.

User and maintenance manuals, which have been made clearer and more detailed over time, provide further help.

 

CASE PACKER CONTROL SOFTWARE

The software installed on the case packer plays a key role in machine communication and, consequently, in predicting any problems.

Signal exchange and alerts with upstream machine - bagging machine / bottling machine, case packer - need to be selected and programmed with a well thought-out logic, to enable operators to predict anomalies and carry out appropriate operations in a timely manner.

Factors positively impacting on such a result are:

  • Experience in packaging processes
  • Cooperation with suppliers of other line machines
  • Software design quality.
 

CONVEYOR BELT SYSTEM

It may seem secondary, but production downtimes can also be prevented with an adequate planning of conveyor belt systems in the packaging plant.

Take the case of a carton jammed in the case packer.

Through careful planning of the belts' length and an adequate set-up of the alert system, operators have enough time to take action before production stops.

Once again, experience in end-of-life packaging plays a decisive role, just like being able to rely on a single contact person to design a packaging plant.

 
Contact us for More: Click Here to Send us an Email

Other news

  • For renowned brand Kerakoll, we have recently developed a wrap-around machine to pack powders for the construction industry in 2 kg and 5 kg bags.

    The format is unusual for this industry, because it targets a specific market: DIY enthusiasts and individuals wishing to do minor maintenance work on their homes.

  • The experience in designing belt conveyor handling systems and automations has taught us that listening to our customers' needs is always the best starting point.

    As is standard practice at Artema Pack, we provide a full range of consulting services to support the client in choosing the best solution.

  • In a packaging plant, an efficient belt conveyor system – both for primary and secondary packaging – plays an important role in terms of functionality and efficiency. It's not just a matter of moving a product or carton from point A to point B.

    The goal is to design a handling system and to unlock its full potential on the basis of products, spaces, production rates, as well as real and complex needs - for both small and large manufacturers.

  • Working in synergy, Artema Pack and Galdi Group were actively involved in the development of the packaging line for Oranfrizer Juice.

  • When designing a packaging plant, nothing can be left to chance and everything can be optimised! Find out more!

  • Let's assume that we are acquiring a new client, who requires a different primary pack (in volume, section or dimensions), in a different packaging format or in a different box type.

    What to do then? Let’s find out!

  • In this article we are going to share five tips for choosing packaging cartons for industrial food products.

  • Artema Pack is your one-stop reference point for all your packaging needs, starting from our qualified and attentive support.

  • As primary packaging, Gable Top allows the product to benefit from properties such as naturalness and freshness, typical of this material.

    For these properties to remain unaltered from the plant through to distribution and end consumers, the same attention must be paid to choosing and developing the most suitable secondary packaging for Gable Top cartons.

    In this article, we will share some tips on how to select the right packaging material and end-of-line packaging solution.

  • How can you choose the right straw or spoon applicator? What needs to be considered? What are the must-have features?

    Let's find out in this article.

     
  • If you already distribute your products using American cardboard boxes, automatic packaging is the ideal choice when production gets busy. For all other Clients, we will try to explain the pros and cons of this type of packaging solution.

  • A shrink wrapping machine (or shrink wrapper), that is, a wrapping machine which uses heat-shrink film, offers considerable savings compared to other end-of-line packaging systems, such as wrap-around or American box.

    At the same time, it allows managing the entire production line with great efficiency.

    In this article, we look at the main features of automatic shrink wrapping machines and the pros and cons of heat-shrink film packaging of food products.

     
  • Food manufacturing and packaging companies make significant investments in their choice of packaging. However, they often underestimate the importance of the right package for safety and branding purposes.

    Wrap-around case packing using trays and boxes is certainly one the most common end-of-line packaging systems.

    But how does it work? And how to choose the most suitable wrap-around case packer?

    We will try to answer these questions starting from the main features of this packaging solution.