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Bringing Flexibility to Breakpack Production

Advanced controls let this maker of banding equipment bring a whole new level of quick-change flexibility to manufacturers delivering ‘breakpacks’ to their retailer customers.

Individual units are fed into the AP-25 bander by the infeed conveyor on the left while banded breakpacks exit on the discharge conveyor on the right.
Individual units are fed into the AP-25 bander by the infeed conveyor on the left while banded breakpacks exit on the discharge conveyor on the right.

CE Madison Banders has introduced its advanced AP-25, a servo-controlled collating and banding solution. The AP-25 automatically creates stacked bundles of individual packages and then bands them with low-cost stretch wrap. Individual units are fed into the AP-25 bander by the infeed conveyor on the left while banded breakpacks exit on the discharge conveyor on the right.Individual units are fed into the AP-25 bander by the infeed conveyor on the left while banded breakpacks exit on the discharge conveyor on the right.

The AP-25 represents the OEM’s first major deployment of servo motor and controls technology from Festo. But before diving into how the controls components make their contribution, it helps to understand that this machine produces what’s known as “breakpacks.” Here’s how breakpacks fit in, using cartoned 100-count aspirin bottles as an example.

Retailers have figured out how many packages of aspirin are sold in a store per day. So suppose Walmart has determined that a store sells six 100-count aspirin bottles per day. Walmart doesn’t want that store getting a case of 24 loose units of aspirin. It wants a 24-count case holding four six-count breakpacks inside so that store personnel can efficiently grab six units to replenish a shelf. Often it’s paperboard or corrugated that’s used to hold the six units in the breakpack. What Madison Banders has come up with is a machine that automatically collates the cartons and forms breakpacks using stretch wrap instead of using paperboard or corrugated.

Keep in mind that while Walmart might want a six-count breakpack, Target may want four-count, and CVS might want three-count. And that’s where Festo came in. Servo-controlled changeover from one format to another takes just minutes. This comes in mighty handy for a contract manufacturer, for example, who supplies Walmart, Target, and CVS, because it lets them efficiently process a high mix of breakpack formats. This lowers labor costs and boosts throughput, both of which contribute to greater profitability. Plus the stretch film used by the AP-25 for banding reduces the cost of consumables compared to paper or polypropylene banding materials.

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