Hints to Controlling a Packaging Line

Along with learning the quirks of the machines you’ll be working with, here are some tips to think about when automating or tuning a packaging line.

Pw 198651 Raybachelorweb 4 2

Some lessons learned the hard way might help someone who has just received the task of automating or tuning a packaging line and hasn’t had that experience yet.

First of all, I would recommend that the automation engineer learn the “personalities” of the machines on the line. Certain machines can cycle quite nicely while other machines can handle speed changes more gracefully than stopping and starting. Some machines like a certain amount of backpressure (containers queued up on an infeed conveyor) in order to improve infeed reliability. There might also be other quirks about any given machine that need to be taken into account when developing the line control logic scheme.

Speed adjustments can have a unique set of challenges to deal with. For example, if glue is being applied to some raw material such as a winder, then how should the glue be managed? It might seem obvious that the glue rate should be simply slowed down in a linear fashion to match the percentage reduction in the speed of the line. Well, I can tell you that what seems obvious isn’t always the case. If the material is paper, that can absorb the glue, and then the glue rate has to actually increase rather than decrease. If the material is something that doesn’t absorb the glue, then I suspect the linear reduction in rate to coincide with the line speed would be a good place to start. If there is some sort of registration marker on the material to facilitate pattern matching on the finished container, and then the line is slowed down, there probably needs to be some adjustment to the timing between when the registration marker is detected and another event such as a cutoff is triggered. In some cases, that timing resolution needs to be more accurate than the timing of a programmable logic controller (PLC) scan can accommodate. In one case, I recall that we had to actually mount the sensor to a mechanism driven by a stepper motor so that we could adjust our timing resolution by simply repositioning the sensor (much like shooting skeet).

Coding, Marking, and Labeling Innovations Report
Explore our editor-curated report featuring cutting-edge coding, labeling, and RFID innovations from PACK EXPO 2024. Discover high-speed digital printing, sustainable label materials, automated labeling systems, and advanced traceability solutions that are transforming packaging operations across industries.
Access Report
Coding, Marking, and Labeling Innovations Report
Pharmaceutical Innovations Report
Discover the latest breakthrough packaging technologies shaping the pharmaceutical sector. This report dives into cutting-edge innovations, from smart containers that enhance patient safety to eco-friendly materials poised to transform the industry’s sustainability practices. All from PACK EXPO. Learn how forward-thinking strategies are driving efficiency and redefining what’s possible in pharma packaging.
Learn More
Pharmaceutical Innovations Report