Discover your next big idea at PACK EXPO Las Vegas this September
Experience a breakthrough in packaging & processing and transform your business with solutions from 2,300 suppliers spanning all industries.
REGISTER NOW & SAVE

Trends in packaging dictate advances in machinery technology and standards

Over the years, machinery and electrical specifications have put on some pounds.

Eighty-plus pages are not unheard of.  And while local codes do add their own arbitrary requirements, these well-intentioned attempts to create internal standards are becoming obsolete as international standards and regulations are increasingly harmonized.

It’s also difficult for specifications created decades ago to fit the level of innovation in the package design, material, machinery and controls spaces today.  Some CPG companies have discovered that the specs that had served them well for years have become a hindrance to innovation. And so, they’ve put their specs on a strict diet of functionality and recognized industry standards.

It’s all about business imperatives, enabling technologies and standards
This guide is all about connecting business imperatives with enabling technologies and the standards that future-proof those investments.  In these pages you’ll find actual specification language you can copy and paste and modify to fit your company’s or your site’s needs.

You’ll also see the trends that are promising to make packaging operations more efficient, safe, productive and accessible to the people who use and maintain them.

The past decade’s advances in packaging machinery came largely from mechatronic designs that traded away inflexible and fixed mechanical motion for more flexible and programmable servo motion, intermittent motion for the higher speeds and reduced noise and vibration of continuous motion, and dedicated motion for robotic flexibility.  These are still highly relevant machine attributes that not all builders have adopted, or adopted to the fullest potential.

But what’s driving the next big wave in productivity?
Look to mainstream technologies for the answers: aircraft, cars, telephones, appliances,
the Internet.

In short, we are making all of these everyday devices easy to access, use and service.  We’re making them capable of self-learning and anticipating our needs.  Smart airplanes virtually take off and land themselves.  Cars have video cameras to see where our rear view mirrors can’t.  Phones have integrated our previously state-of-the-art but separate email, GPS and Web functions into one device.  We can program our home appliances from these phones.  And of course, everything is connected to the Internet, from the cloud to…you guessed it…the packaging machine.

In a word: convergence
In recent years, we’ve seen the motion controller converge with the PLC, then with the touchscreen HMI.  Robotic kinematics were integrated into general motion control and the device network merged onto the motion network.  Integrated (and open) safety systems can run over that same network and plug into the same hardware backplanes.

At the same time, we’ve watched the hardware converge into a single platform alongside the software integration.  When it comes to specifying the control system for a packaging machine, it is getting harder to justify an argument for a premium priced standalone PLC with special modules for motion, a separate HMI panel incapable of doing much else, and a PC for handling things like production data acquisition, vision and serialization systems, and possibly interactive work instructions for operators and troubleshooters.

Different automation cultures, divergent perspectives
In North America, the automation industry has learned to avoid the term ‘PC-based control’ – because too many engineering managers lived through Windows NT and CE, with hard real-time operating systems that relied on watchdog timers and schemes to interrupt Windows.  This led to an abject fear of the ‘blue screen of death.’  There were claims by soft logic suppliers that cheap ‘whitebox’ PCs from Walmart could substitute for industrial PCs.  And of course at the time we didn’t have massive Flash solid state drives, and many spinning disk drives failed on the factory floor.

While the allure of PC-based control in the mid-1990’s was well-founded, the immature software and hardware of the early days were not sufficiently robust for industrial applications, causing many machine builders and packagers to rethink switching.

In Europe, they never feared ‘PC based control.’  In fact, they embraced the relevant force driving their advances – a combination of Moore’s Law and recognition that control applications like logic and motion should not be dependent on hardware configurations.  They are in fact software functionalities that happen to run on hardware.

The same holds true today for safety networks, which are really protocol extensions running on the application layers of the various flavors of industrial Ethernet.  Once you think in terms of software, you free yourself of increasingly irrelevant and limiting classifications like PLC and PAC.  What you really need is the appropriate control hardware to run the software that delivers the desired functionality.

See the coming convergence?
Once you gain the benefit of Moore’s Law you catch a ride on the incredible, ongoing rise in processing power and the simultaneous drop in processor cost that high volume, mainstream computing markets have created.  That’s exceptionally true today with mobile computing and device markets that have led to powerful multicore processors and economical, compact processors that run cooler, consume less energy and withstand vibration and ambient temperature extremes.

The formula includes a proven real-time operating system that is totally separated from and has absolute priority over Windows.  This requirement has been clear and deliverable for over 15 years, driven by mission critical computing applications in the medical, energy, telecom and aerospace industries.  Much of PC-based control’s bad rap came from using a real-time operating system that interrupted the hardware abstraction layer (HAL) of Windows™ instead of running Windows in the background.

Annual Outlook Report: Automation & Robotics
What's in store for CPGs in 2025 and beyond? <i>Packaging World</i> editors explore the survey responses from 118 brand owners, CPG, and FMCG <i>Packaging World</i> readers for its new Annual Outlook Report.
Download
Annual Outlook Report: Automation & Robotics
Is your palletizing solution leaving money on the floor?
Discover which palletizing technology—robotic, conventional, or hybrid—will maximize your packaging line efficiency while minimizing long-term costs in this comprehensive analysis.
Read More
Is your palletizing solution leaving money on the floor?