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Exiting the capper cans convey past a Videojet ink-jet coder that marks them with contract number and code date. Then a spiral conveyor from Multi-Conveyor elevates the cans from nearly floor level up to the level of the case packer infeed conveyor. The drop packer which loads six cans per case two cases at a time was supplied by Hamrick.
“We had an older machine from Hamrick and we liked it” says Butler. “This new one has a vacuum-assist feature that holds the 12 cans to soften the impact as they’re dropped. That helps prevent denting and reduces the risk of any sudden shock or impact causing the cap to come out.”
Cases are erected by hand but glued shut with hot melt glue by a Wexxar case closer. Just ahead of the Wexxar unit is an ink-jet coder from Kiwi that puts contract number and date on the side of each case. Immediately downstream from the Wexxar machine an elevator takes cases up to an overhead level and then to the infeed of a VonGal palletizer.
“We used to palletize by hand” says Butler. “These cases are just too heavy for that.”
A Lantech stretch wrapper brings the line to an end. “It keeps up not only with the Serac line but also with the output of an in-line filler that we sometimes use for these 4-L cans during peak production periods” says Butler.
Capabilities like these are what enabled the firm to produce more than 80 million pounds of oil in the 4-L format last year.
Mechatronic magic
In a completely separate room at ARC-Diversified are packaging lines for powdered bakery mixes and instant milks. Some of these are packaged in #10 cans others on vertical form/fill/seal machines and still others on a bulk bag system.
All five of the vf/f/s baggers running at ARC-Diversified were supplied by Rovema. The two most recent arrivals a Model VPK-260 and a VVI-200 represent significant advances in controls technology or as it is often called today mechatronics.
The newly installed VPK-260 features ControlLogix from Rockwell an integrated controls solution that lets one controller handle both logic and motion. Both VPK-260s installed previously at the plant relied on a more conventional controls architecture in which a PLC handles sequential functions—i.e. logic—and a motion controller handles motion.
“This new controls architecture represents an important advancement in terms of reduced parts and ease of supportability” says Travis Holley of Rovema. “Since there is only one controller for the machine there is less wiring. All motion and logic functions are handled by the ControlLogix system so there is no need to wire a communications link between separate motion and logic controllers.
“From a support standpoint a key advantage is that you no longer have one software program for the PLC and another for the motion controller. There’s one program. And because it’s IEC 61131-3-compliant no special programming language is required. More people can support such a system.”
Complementing the Rockwell controller is a SERCOS fiber-optic bus that carries all digital communications to the five servo drives connected to the five servo motors responsible for the following axes of motion: cross-seal jaws two film-feed belts zipper material infeed and film index for zipper placement on the film.
“The SERCOS bus delivers more than just position data” says Holley. “There’s a phenomenal array of drive and motor status information that helps a lot in maintenance and troubleshooting.”
Motorized forming set
At a nearby ARC-Diversified facility that’s also in Cookeville another Rovema bagger the VVI-200 also benefits from Rockwell’s ControlLogix integrated logic/motion solution. But while the VPK system is a continuous-motion machine the VVI-200 is intermittent. Also setting it apart is a patented bag-forming set that is adjustable at the push of a button. So when the production schedule calls for a new bag size there’s no need for mechanical removal of one forming set and installation of another. Instead the operator goes to the HMI panel and dials in the new bag size. The patented motorized forming set connected to the ControlLogix controller by an absolute feedback device moves to whatever position parameters the new bag size requires.
ARC-Diversified is the first Rovema customer to install a VVI-200. “The versatility we gain in this machine is really helpful” says Butler. “We can go from a 40-g bag to a 1-lb bag at the push of a button. It can be done in minutes.”
Butler adds that the machine has two motorized forming sets. One is for a range of bags from about 23¼4” to 5” in height; the other is for bags from 51¼2’ to 11” in height.
Additional versatility comes from the orientation of the jaw set which is rotated 90 degrees from the position typically found in most conventional vf/f/s systems. This makes it possible to produce three- or four-side-sealed bags.
Butler is especially pleased that despite its ability to produce so many different bag sizes and formats the machine’s footprint is still very small. Speeds are good too he adds. “It runs at 120 cycles/min.”
- »Videojet Technologies Inc.
- »Kiwi Coders Corp.
- »Lantech Inc.
- »Serac Inc.
- »Hamrick Mfg. & Service, Inc.
- »Multi-Conveyor
- »Wexxar Packaging Inc., a division of Pro Mach
- »Rovema Packaging Machines L.P.
- »Rockwell Automation
- »Lock Inspection Systems
- »Contract Packaging Inc.
- »Flexicon Americ
- »VonGal, a division of HK Systems
- »Chantland Co
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