View news and innovations from PACK EXPO 2024
View all the latest news and innovations from PACK EXPO International 2024

Report: Innovative New Controls at PACK EXPO Las Vegas

PMMI Media Group editors fanned out across the many booths at PACK EXPO Las Vegas to bring you this Innovations Report. Here’s what they saw in the controls category.

Image #1 in the article text.
Image #1 in the article text.

Retort manufacturer Allpax, A ProMach brand, saw PACK EXPO Las Vegas as an opportunity to debut a solid-state digital chart recorder (1) that Image #1 in the article text.Image #1 in the article text.offers data recording and data integrity benefits and eliminates deviations common to paper charts.

“In a typical retort installation, the operators have lots of things to do. Even though standard control systems prompt them to do certain things, so many people are still printing out manual records—and each record for each process can be two or three pages—then they have to review it and sign, then it has to go to a quality assurance person to review and sign, and so this is one of the steps we’re taking to eliminate the paper trail and make everything all electronic, and still validated by the FDA, USDA, etc.,” a representative from Allpax told Packaging World at the booth in Las Vegas.

This digital device offers safe and secure data storage, fully compliant with the regulatory requirements of 21 CFR Part 11 for electronic record keeping. When connected to a printer, the device can be setup to automatically print the process record trends to a paper report at the end of each batch period, thus allowing it to serve as the official Temperature Recording Device (TRD) in both electronic record keeping systems as well as legacy record printing systems. The presentation of the electronic data and the printed data is specifically designed to improve the record review process and thus reduce risk and increase efficiency in the review process.

Additionally, the digital chart recorder eliminates the typical process deviations caused by print skipping, improper paper installation, and the other issues associated with mechanical chart recorders. Installation is easy—simply move the wires from the mechanical device to the new Allpax digital device.

Image #2 in the article text.Image #2 in the article text.For those migrating toward electronic record keeping, the Allpax digital recorder can be installed alongside an existing pen-and-paper recorder and function as an electronic backup. This Allpax solution eliminates paper-chart deviation issues caused by paper jams, skips, dry ink, pen adjustments, paper replacement, and incorrect paper installation. The Allpax digital chart recorder is compatible with both batch and continuous retorts. This device records real-time data and graphically displays it in a user configurable format. Each input parameter can be displayed clearly and understandably. Custom definable ranges, scales, and chart graduations optimize legibility and adhere to the best practices described under 21 CFR Parts 113 and 114. The Allpax digital chart recorder stores electronic records in a secure Microsoft SQL server database. Password security with fingerprint traceability of all device interactions ensure data integrity. The device also offers customizable on-screen notifications and alarms with the ability to send these messages via e-mail.

Predictive maintenance

Featuring the industry’s first, patented bottom-bearing wear sensor, the Ashworth SmartSpiral monitoring system (2) takes the guesswork out of when an Ashworth spiral conveyor system will fail. It allows access to multiple spiral systems at multiple plant locations from a phone or tablet to continuously monitor temperature, belt tension, and cage power. Live data is collected and transferred via a proprietary application to a cell phone, tablet, laptop, or desktop computer—without having to use an intranet system. The monitoring system helps prioritize maintenance costs, identify performance issues, prevent failures, and reduce repair costs to improve performance and efficiencies.

According to Ashworth Bros. Senior Product Engineer Chris Trinch, “We designed our SmartSpiral monitoring system to help users run their spiral systems correctly. We monitor data from five different locations in a spiral. We take that data, analyze the alarms, and store that information, which is then sent to our customer, giving them knowledge that makes a real impact.”


Watch video   

Watch a video of the Ashworth innovation.


Exhibiting for the first time at PACK EXPO, Llumin, an established participant in the Computerized Maintenance Management System (CMMS) space, introduced a new software called Llumin for OEMs. Previously, offerings from Llumin like its Llumin CMMS Suite were aimed more at Consumer Packaged Goods companies and other manufacturers. Such cloud-based software, interfaced with a machine’s control system through OPC, MQTT, or Modbus, captures machine usage data, for example, to create periodic Preventive Maintenance schedules, which then automatically generate work orders in a streamlined process.

“Llumin for OEMs is built on the same core architecture,” says Llumin CEO Ed Garibian. “But we’ve taken our years of experience in maintenance and predictive remediation and have built a product for the machine builder so they can monitor in a super effective way the machinery operating in their customers’ plants. They can also set rules for automatic spare parts replenishment or automatic service calls, and they can do a better job of analyzing how their machine is performing throughout their customer ecosystem.”

Garibian adds that this new platform is a good fit for any packaging machinery OEMs who want to add a Machine as a Service (MaaS) option to their offerings. This use-based finance model, similar to SaaS (Software as a Service), is a flexible way to install automation on the factory floor without having to invest capital upfront. Instead, the machine user pays for a successful outcome based on a predetermined agreement around productivity.


Read article   Read this article for more information about MaaS.


Among the early adopters of Llumin for OEMs is Sleeve Seal, a maker of equipment that applies shrink sleeve labels.

Servo-pneumatics

Among the various automation and control trends apparent at PACK EXPO Las Vegas, the growing combination of pneumatic and electric automation, such as servo motion control, could be seen at the booths of both Emerson and Festo. Image #3 in the article text.Image #3 in the article text.

Emerson showcased its smart pneumatics and servo motion systems that feature advanced analytics and edge computing to help users increase productivity and profitability as well as meet sustainability targets. Emerson refers to this combination of pneumatics and servo motion as servo-pneumatics, a technology mix used widely in packaging applications. Pneumatic positioning is preferred by many OEMs and consumer packaged goods manufacturers because of its budget friendliness and ability to reduce machine development time.

A key aspect of Emerson’s servo-pneumatic approach begins with a filter regulator assembly, which is used for conditioning the air quality before it enters the servo-pneumatic system. The air pressure from the filter regulator unit then leads into proportional valves that enable the force, speed, and position of the actuator to be controlled. As pressure on both sides of the valve’s piston is regulated, digital pressure sensors in the system allow real time data from the proportional valves to be viewed. A hygienic, IP69K-compliant actuator with a built-in measurement sensor tracks the piston position, completing the closed-loop system back to the controller. Emerson’s Advanced Electronics System control unit allows for direct communication to a PLC via multiple fieldbus protocols. It also contains a PID module to control the proportional valves based on position or force commands from the PLC.

The servo motion aspects of the system highlighted by Emerson showcase the combination of PLC and motion controller in one backplane, allowing for the motion controller to communicate with the PLC directly through the backplane. Because the backplane also powers the unit and handles communication, this creates an integrated system for servo-pneumatic applications. Each motion controller/PLC system can communicate with up to four axes and will automatically synchronize and communicate with additional systems as they are added to a line to control more axes as needed.

From a motion control perspective, this system can handle a 1-millisecond path planning loop, a 500-microsecond position loop, and a 250-microsecond communication loop over EtherCAT regardless of how many axes are being controlled in the machine. The servo motion controller also allows for motion profiles to be changed on-the-fly as machine applications change.

Emerson’s Aventics AF2 smart flow sensor (3) is used to identify when equipment is wasting energy and to prevent downtime. It measures air flow and pressure, as well as energy being used with readings displayed on the AF2’s built-in OLED screen. Statistical data gathered by the sensor calculates the cost of air being used by the equipment. Alerts can also be sent when acceptable operating parameters are not met to avoid unplanned downtime.

The sensor can be connected with an industrial or Power over Ethernet (PoE) M12 interface. The industrial version offers analog, frequency, switched, and IO-Link outputs, allowing users to capture data on a PLC or other industrial controller. The Ethernet PoE version supports many of the open protocols being used in IIoT systems, such as MQTT and OPC UA, enabling connections to existing OEE (overall equipment efficiency) monitoring software or larger cloud systems. Data from the Ethernet PoE sensor can be viewed in real time on the device’s internal web server or via any computer or monitoring system connected to the same network.

Warren Pruitt, vice president of Global Engineering Services at Colgate-Palmolive Company, says Emerson’s AF2 smart flow sensor technology is helping Colgate-Palmolive “achieve our energy goals by reducing wasted compressed air, which ultimately reduces our carbon footprint. The AF2 Smart flow sensor identifies wasted energy from our compressed air delivery system and its connectivity through OPC UA allows for seamless data streaming.”

Image #4 in the article text.Image #4 in the article text.Meanwhile, Festo showcased its new Simplified Motion Series (SMS) all-in-one integrated-drive axes (4). The company says SMS represents an “engineering breakthrough” in that it combines pneumatics with electric automation. This breakthrough is based on how Festo’s SMS integrates ball screw axes, toothed belt axes, mini slides, electric cylinders, piston rod, and rotary actuators with an onboard servo drive.

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