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Future shock

Leading packagers chart a course into the 21st century of packaging technology.

As this century hurtles to a close, Packaging World asked experts at some leading packagers to envision the crucial technological advances in machinery and materials that are required to move packagers into the next millennium. There was only one rule: throw out the rulebook.

The number one area in need of a profound change, according to almost everyone we spoke with: quicker changeover. Although machinery builders have made great strides in this area, packagers say such capabilities haven't kept pace with the trend toward shorter, more frequent runs due to package proliferation and the quickening pace of new product launches.

What specifically do packagers need to make changeover easier and faster? No one disputes that no-tool changeover equipment is desirable, but some packagers want equipment that can take drop-in change parts with zero adjustments. At least that's what customers, many in the pharmaceutical industry, are telling Bill Cegles, president of C-F Packaging, a Greensboro, NC-based packaging consulting and systems design firm. For example, screw-on parts are time-wasters and should be eliminated, he says.

"Packagers just want to swap out the parts, push a button and start running," says Cegles.

A packager in the personal care industry wants to go one step further. "I've bought my share of change parts over the years, but I hope one day I don't have to buy any," says Paul Redwood, packaging systems manager at Unilever Home and Personal Care Products at its Raeford, NC, plant. "To me the ideal packaging machine would require no change parts."

As Redwood sees it, while change parts may add flexibility to a packaging machine, there's an insidious underside. "The idea of change parts tells our marketing groups that we can make something happen quickly, but all it does is introduce inefficiencies in our operation."

The changeover bottleneck also interferes with the heart of what many feel packaging's all about: using creative shapes, sizes and materials to garner consumer attention in an overcrowded marketplace.

"We actually don't commercialize a lot of the prototypes we develop in R&D because the shapes are so unique that today's packaging equipment won't handle it," says Joe Haake, R&D packaging manager with Coors Brewing Co., Golden, CO. This from the company that marketed a bottle in the shape of a baseball bat (see PW, May '96, p. 8).

Computerized maintenance

Maintenance improvements struck a chord with several interviewees as a key need. Redwood wants packaging equipment of the future to be "self-managed." Software running on the machine should be able to monitor the hours logged on the machine, and at the appropriate intervals, print out a schedule of preventive maintenance items that need servicing. Such software should also be able to produce a printout of the needed parts, including part numbers. This list could then be faxed to the vendor so that parts arrive in time for scheduled maintenance periods or shutdowns.

The software already exists, says Redwood, but he believes machinery builders need to do a better job of integrating such software into their machines, he says.

The increasing use of graphical operator interfaces, known as human-machine interfaces (HMIs) on modern packaging equipment, also creates an opportunity for simplifying maintenance. Already many machines can display blueprints of the relevant portion of the machine while a mechanic is making the repairs.

With networking, it will be possible for the mechanic to order a replacement part right from the HMI screen. The part number could be transmitted from the PC that runs the HMI, across the factory network and over a secure Internet connection right to the supplier.

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