festo electric drives in tetra pak filling machines
TRANSCRIPT
Festo Electric Drives in Tetra Pak Filling MachinesAfter two years of intensive development and testing, Festo has
developed a customized brushless motor solution suitable to meet
all customer requirements. An open door for future Tetra Pak
applications for Festo electric drives!
For more information: www.festo.com/us/food
Tetra Pak develops and manufactures complete processing, packaging and distribution systems forfood.
Their business has expanded to include more than justpackaging liquid food products. Ice cream, cheese, dryfoods, fruit, vegetables, pet food are also productsthat can be processedor packaged in Tetra Pakmachines.
Tetra Pak products are divided into several differentcategories such as packaging, processing equipment,filling machines, distribution equipment and serviceproducts. The filling machines A3 Flex, A3 Speed andA3 Compact Flex are three important machines of theTetra Pak core range, developed in Italy and producedboth in Italy and Austria.
These three different configurations have been createdto meet the demands of all Tetra Pak customers: A3 Flexis a flexible filling machine for medium-sized customersin rapidly changing markets, A3 Speed is perfect for customers handling bulk production and high pack num-bers that are produced on one machine, and the A3Compact Flex is used for portion packs where space islimited but the same flexibility as the A3 Flex is needed.
Tetra Pak has chosen Festo as its partner for the development of a new special motor solution toreplace the existing Sick HyperDrive which is mountedon the A3 Flex and A3 Speed filling machines. The project started in 2011 and is seen as an applicationreference so that the same solution can be installed inother Tetra Pak machines.
Application descriptionStarting from a reel, the packaging material goesthrough a sterilization process. At the end of the fillingmachine, the packaging material is formed into a tube,then sealed, filledand cut and the package is shapedinto its final form.
A motor system is used in the non-splash zone for theadjustmentof the tube forming rotation and, in some cases,a small volume adjustment of the package. Therequirements of Tetra Pak were for a Festo motor with
integrated controller with a higher performance than the oldSick solution. In addition, Tetra Pak asked for additional features such as NSF-H1 lubrication on the gearbox, alreadyuploaded parameters, gearbox with a special design, different connectors for DeviceNet and the power supplyand the ability to avoid any homing at the customer's site.Tetra Pak also required a motor with an angular gearbox sothat it could be mounted in places where space wasrestricted.
Festo Corporation
Commercial support:Call: 1.800.99.FESTO (1.800.993.3786)Fax: 1.800.96.FESTO (1.800.963.3786)Email: [email protected]: www.festo.com/us
Technical support:Call: 1.866.GO.FESTO (1.866.463.3786)Fax: 1.800.96.FESTO (1.800.963.3786)Email: [email protected]
After some considerations it was decided that theCAP30 Applicator, a complete distribution unit for applying all caps available on the market, needed fivemotors for its quick format change.
The Festo solutionIn cooperation with Tetra Pak we installed an MTR-ECImotor able to fulfil all the requirements.
Festo has developed a brushless motor with absolutemultiturn encoder and the following special features:
MTR-ECI-52R-MG25-R3DN-FG-SA, straight gearbox• NSF-H1-H1 lubrication on the gearbox• Special drawing gearbox with ratio 25:1• DIP switch next to the LEDs with a protective foil forDeviceNet address selection• M12 and M16 connectors for DeviceNet and the powersupply• Special dedicated firmware
MTR-ECI-52R-MW33-R3DN-FG-SA, angular gearbox• NSF-H1-lubrication on the gearbox• Special drawing gearbox with ratio 33,3:1• DIP switch next to the LEDs with a protective foil forDeviceNet address selection• M12 and M16 connectors for DeviceNet and the powersupply• Special dedicated firmware
Final result
The project took two years and there were timeswhen the end result seemed hard to achieve.
In the end Tetra Pak signed a Customer ApprovalAgreement recognizing Festo as a unique motorsupplier for this application for volume and rotation adjustment and format change with a forecast of 500 motors per year.
Tetra Pak started to order both versions in February2013. The excellent effort, support and very closecooperation between the Development ElectricDrives department in headquarters and the KeyAccount Team were our key strengths and seen asour main added value by the customer.