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Flexible Packaging Playbook Strategies
In this newsletter • End-of-line buffering • Case study: Rock-steady pallet stacker • New Equipment
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Automatic adhesive fill systems offer surprising results that help manufacturers minimize line downtime, increase productivity and reduce contamination and waste. Download this white paper to find out what's important when selecting a system that incorporates easily into your line with long- and short-term benefits.
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Complete End-of-Line Solutions from A to Z Complete End-of-Line Solutions from A to Z
Providing a single source for your end-of-line needs is what Z Automation is all about. Whether ZAC is integrating a cartoner or sleever with one of our modular case packers. ZAC will ensure that your line runs, smoothly, efficiently, and cost effectively. Contact us to learn more about our integration solutions.
Z Automation Company
MARCH 29, 2012
Best practices for buffering
and end-of-line design
There are some special considerations for packaging line buffering as it relates to the end of the line:
1. Set increasingly high capacity downstream. A rule of thumb is for the first machine upstream to have 110% the capacity of the second, and so on, at by intervals of 10%. If calculations show that a piece of modern equipment has 95% availability, this can be pared to allow the downstream machine to draw product away at 5% faster when run in a catch-up mode to avoid back-ups. A 150/min bottling line that experiences five minutes of 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 after a downtime incident. Over-specifying downstream capacity is a key to recovering from stoppages. It also helps smooth out system flow perturbations.

2. Find the line's "sweet spot" by determining the process centerline. Some lines run best at breakneck speed; others are most efficient at a slow and steady pace. Practitioners of the manufacturing and packaging art often make the mistake of setting speeds too high, too close to design specifications. One failure can be disastrous to productivity. Installations vary, but trial and error become evident when you document your results to arrive at the optimal combination of speed and product quality on a balanced line with minimal upsets or downtime. Trained personnel can choose from a wide array of statistical analysis tools to arrive at the right speed for your equipment and overall line.

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Packaging World’s free, comprehensive End-of-Line Equipment Playbook jam-packed with strategies for success, best practices, and pitfalls to avoid.
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Case study
A more stable stacking solution for cement mix bags
'Rock-steady' pallet stacks and use of readily recyclable bags win over customers.
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Supplier News
Blue Line
Pro Mach expands end-of-line capabilities and case packing footprint with acquisition
of Edson Packaging Machinery
Intelligrated expands Mason, OH headquarters to accommodate
local job growth
Dynamic Conveyor promotes Tom Habetler to support growing
Michigan customer base
MG America named exclusive distributor for Promatic and Macofar lines of Romaco machinery >>
New Equipment
Columbia Premier Tech August-Zaller
Conventional palletizer with robotic capability Robotic palletizing cell August Faller's new line codes and prints pharmaceutical folding cartons
Yellow Jacket Schneider Brenton
Orbital stretch wrapper saves money, time, space Horizontal case packer Reducing case packer cost and complexity
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High-speed palletized infeed
High-speed case turning and laning system from Intralox features non-contact case turning at up to 225 cases/min and downstream laning portion that keeps pace.
Packaging Technology Roundtable on May 23
The Automation Conference, May 22-23 at the Hilton Rosemont will feature a Packaging Technology Roundtable with Kai Mariappan, Coca-Cola; Tom Doney, Nestlé Engineering (Chair of OMAC Packaging Workgroup's PackAdvantage); and Joe Grove, of Ossid LLC, a ProMach Company. Topics include integrating packaging and business systems; real-time data acquisition to improve OEE; developments that enable machine builders to deliver flexibility and fast changeover.
Learn more »
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