playbook endofline v9 opt

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packagers playbook serieseducation for packaging professionals 2012 Edition

8 Cartoning through stretch wrapping 8 Packaging equipment project strategies

8 Glossary of terms 8 Downloadable vendor evaluation tool

END-OF-LINE

EQUIPMENTPlaybook

HOW TO SUCCESSFULLY

IMPLEMENT

ENd-OF-LINE PaCkagINg

EqUIPMENT PROJECTS


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packagers playbook serieseducation for packaging professionals

SPONSORED BY2012 Edition
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packagers playbook serieseducation for packaging professionals

SPONSORED BY2012 Edition

iconotechGeneric Case Printers
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End-of-Line Packaging Equipment Playbook

CONTENTS4 / 100

INTRODUCTION

8 Your playbook or building a better packaging line

CONTRIBUTORS6 Brand owners, consultants and engineering experts

contributing to this playbook

10 Best practices or buering and end-o-line design

13 Eight tips or selecting cartoning equipment

17 Ten tips or buying coding/marking equipment or cases and pallets

23 Trends in case packing equipment28 Checklist or buying case packing equipment

31 Best practices or selecting case packing equipment

35 Wraparound versus RSC cases

36 Glossary o case packing terms

44 Nine tips or selecting multi-packing and shrink bundling equipment

48 What to look or when selecting palletizing equipment

EQUIPMENT STRATEGIES
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CONTENTS5 / 100

PROJECT STRATEGIES

58 Ten nancial justications or new equipment

62 Best practices or speciying packaging machinery

69 Vendor evaluation methodology or packaging equipment

71 Tips on nding the right equipment supplier

78 Roadmap or a successul Factory Acceptance Test

86

Ten tips or a successul packaging line start-up91 Automation trends strategies or packaging machinery

96 How projects ail: 11 pitalls to avoid

52 Trends in robotics and best practices or buying and speciying

55 Best practices or speciying stretch wrapping equipment

EQUIPMENT STRATEGIES (CONTINUED)
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CONTRIBUTORS

Paul ZePf

P.Eng., M.Eng., CPP

Zarpac Inc.

With nearly 40 years o packaging production

experience, Zep has written 14 books on packaging

production technology and is a co-ounder o Zarpac

Inc., an engineering, sotware, and consulting frm.

Paul Redwood

Sr. Research Engineer

Church & Dwight

Shawn fRench

Engineering Director

Dannon

Matthew couRteSiS

Packaging Dept. Supervisor

Boston Beer

Sunny iShikawa

Engineering Research Fellow

Wrigley

GReG flickinGeR

VP Manuacturing and Corporate Engineering

Snyder's-Lance, Inc.

The ollowing brand owners, consultants and engineering experts contributed to this playbook

adaM PawlickDirector o Packaging

Bay Valley Foods

Glenn whiteSide

Packaging Engineer, CPP

Synthes (USA)

dave hoeniG

Principal

DH Technical Consulting, LLC
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CONTRIBUTORS

We grateully acknowledge the expertise othese supplier contributors:

All-Fill, Cozzoli Machine Co./MRM/Elgin, Delkor Systems, Douglas

Machine, Econocorp, Inc., EDL Packaging Engineers, Fanuc Robotics,

Grin-Rutgers, H.B. Fuller, Hartness, Intelligrated, Lantech, MGS

Machine, Pearson Packaging Systems, Schneider Packaging

Equipment, Spee Dee Packaging Machinery, Videojet, Yamato

Several other brand owners were interviewed

or this playbook on the condition o anonymity.

SteRlinG anthony

Consultant

toMMy lancaSteR

Chie Operating Ocer

Bryson Industries

cuRtiS waRdauGh, P.e.

President

Medalist Engineering, P.C.

Additional contributors:

Keepcurrentwithafreeprint

subscription!

330 N. Wabash Ave., Chicago, IL 60611 phone 1-800-355-5595 www.summitmediagroup.com

www.packworld.com/subscribe
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FORWARD ADD COMMENT


INTRODUCTION

RETURN TO CONTENTS

By david newcoRn

VP/Digital & Custm Mdia

Packaging World

Your playbook or buildinga better packaging line

Anyone whos worked in packaging machinery engineering knows that speciying and

installing a modern, automated packaging line is essentially an exercise in eective

management o literally thousands o details. As little as one misplaced assumption can

delay or sink the project. No wonder projects can be overwhelming at times to even themost seasoned proessionals.

Thats why we conceived this Playbook. We wanted to create one source that spells out all

the tricks and tips associated with buying, testing, commissioning, and starting up packaging

equipment. To unlock these secrets, we spoke with or consulted with over 45 sources. Most

o these consisted o in-depth phone interviews with experts in the eldengineers and

managers at leading consumer packaged goods companies.

We also talked to suppliers, who gamely set aside their sales hat and spoke honestly about

best practices and pitalls to avoid. Remember that while you may buy one ller or inspection

system or coding/marking system in a given yeari that manythe companies selling

that equipment have been through dozens o projects in that same time period. Learn rom

their experience.
http://www.packworld.com/playbook/forward/end-of-linehttp://www.accelacomm.com/jaw/source/67/50112540/http://www.accelacomm.com/jaw/source/67/50112540/http://www.packworld.com/playbook/forward/end-of-linehttp://prevpage/


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INTRODUCTION

RETURN TO CONTENTS

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In short, what youre reading is the collective thinking o an industry, representing hundreds

o years o packaging experience, distilled into a short, actionable, bulleted style that makes

or easy reading.

This particular playbook is brand new or 2012, coming on the heels o our successul

playbooks in the area o fexible packaging, labeling and package development (all o

which are updated or 2012, by the way). In this playbook, we cover the back hal o the

packaging line, rom cartoning, case packing, and shrink bundling through palletizing

and stretch wrapping. You will denitely want to download the Primary Packaging Line

Equipment Playbook, which covers everything on the ront hal o the packaging linerom

unscrambling through induction sealing. The two playbooks will equip you well or your next

project. (See all our playbooks atPackworld.com/playbook.)

All o our playbooks are designed to be read either on the screen, or printed out.

A nal word. The entire cost o producing and distributing this playbook has been

underwritten by the companies who have sponsored it. We thank them or their support,and we thank you or reading.

continued

Your playbook orbuilding a betterpackaging line
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Best practices or bueringand end-o-line design

There are some special considerations or packaging line buering as it relates to the

end o the line:

1. Set increasingly high capacity downstream. A rule o thumb is or the rstmachine upstream to have 110% the capacity o the second, and so on, at by intervals o

10%. I calculations show that a piece o modern equipment has 95% availability, this can

be pared to allow the downstream machine to draw product away at 5% aster when run in

a catch-up mode to avoid back-ups. A 150/min bottling line that experiences ve minutes o

downtime will need downstream equipment to absorb 750 bottles. The key is to have 20%

to 40% extra speed and capacity downstream to allow the line to catch-up ater a downtime

incident. Over-speciying downstream capacity is a key to recovering rom stoppages. It also

helps smooth out system fow perturbations.

2. Find the lines sweet spot by determining the process centerline.Some lines run best at breakneck speed; others are most ecient at a slow and steady

pace. Practitioners o the manuacturing and packaging art oten make the mistake o

setting speeds too high, too close to design specications. One ailure can be disastrous to

productivity. Installations vary, but trial and error become evident when you document your

ByBoB SPerBer,

Spcial Pjcts edit
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continued

Best practices or buering

and end-o-line design

What Can Bergami Do For You?

610.588.3900www.bergamiusa.com

INNOVATIVE PACKAGING

MACHINERY SOLUTIONS

Cartoning Systems

Intermittent or Constant Motion.

All Speeds and Applications.

Wrapping/Bundlewrapping Systems

All Speeds and Multiple Applications

Fully Automated Casepackers

Vertical and/or Side Loading as Required

Casepackers-Palletizers Combinations

Ultra Compact Footprint

Palletizing Systems

Single Pallet Systems or Multiple Pallets Multiple SKU

Laser Guided Pallet Handling

and Complete Warehouse and Material Automation

results to arrive at the optimal combination o speed and

product quality on a balanced line with minimal upsets or

downtime. Trained personnel can choose rom a wide array

o statistical analysis tools to arrive at the right speed or

your equipment and overall line.

3. Leave sucient space between machines.Just as automated lines are oten set to run too ast,

machines on automated and highly integrated lines are

oten spaced too closely to one another. I automation

isnt state o the art and ully trusted, plan sucient space

between machines and stations to allow or placement

o buer zones. Designing in reliable unit operations can

help to minimize buering requirements, so i foor spaceis at a premium, ocus on equipment reliability, especially

generous tolerances or material variations.

4. Prevent stoppages at the case packer. Casepackers can be sources o ineciency, as seen in situations

where corrugated or gluing ails to meet specications.

This can back-up upstream processes and cause upstream
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line stoppages and reworks, wasting all the eorts to

maintain high production eciencies upstream. Buering

can be minimized or eliminated when o-spec product and

materials are quickly, automatically inspected and rejected

rom the line to prevent hiccups. Bear in mind that it can be

very dicult to put containers back into a close-coupledline without knocking over other containers and causing

urther problems. Choose your case packing solution well,

with reliability carrying just as much importance as speed.

5. Dont let your accumulator reach topcapacity. For some accumulators, such as a verticalcarton accumulator, a completely lled accumulator

requires the line to be stopped and cartons to be unloaded.I theres not enough foor space to unload them, or i the

downstream machine isnt suciently ast, you may nd

your line running an empty ller.

Remember reliability is king and buering is your

insurance policy.

continued

Best practices or buering

and end-o-line design

A leader in the packaging world, Eastey Enterprises has been

making the industrys avorite shrink packaging equipment or

over 25 years. Our products are MADE IN THE USA so expect

eatures like all-welded rames made o 1/4 cold-rolled steel,

casted seal heads equipped with double locking bolts, and

proven quality and reliability to keep your packaging line up

and running day ater day.

Contact Eastey today and discover your frst and last choice in

shrink packaging equipment.

(800) 835-9344www.eastey.com
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Eight tips or selectingcartoning equipment

Here are some tips to keep in mind when purchasing cartoning equipment:

1. Know thysel. Choose cartoning equipment based on how it works in your specicplant, with your compressed air system, and with your blanks.

2. Consider the nature o the product when choosing either vertical orhorizontal equipment. The product will dictate the type o cartoning machine needed.For example, i the product is ree fowing (granular in nature like detergent powder or loose

pieces like boxes o cough drops), you may be able to ocus mainly on vertical-style cartoning

equipment. However, or products that can load horizontally or vertically, horizontal

equipment is oten better. Most cartoning machines are horizontal loaders. Generally, they

perorm with more fexibility at a lower cost.

3. Determine the most productive speed. First determine i the operation willbe on line or o line. For on-line speed, calculate the maximum rate possible to make the

product and divide it by the number o products per carton. Then actor in surge capability:

the potential to increase the rate via new processes or technologies. For o-line speed,

consider the daily, weekly, or monthly shipping quotas. Make sure to use realistic numbers or

days per week and true hours per day to calculate required cartons per minute.

By MaRty weil


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continued

Eight tips or selecting

cartoning equipmentThe confectionery plant "Ozersky Souvenir" is oneof the largest manufacturers of confectioneryproducts in Russia.

All sweets are being produced on advancedequipment of European manufacture. Exclusivetechnologies are developed and applied atOzersky, that along with special attention given tousage of natural raw materials, allow to createproducts of the highest quality with unique taste.

The customer consequently turned to CamaGroup, a leading supplier of advanced technologysecondary packaging systems, to engineer its

packaging lines to allow the company to meet theexceeding market demand.

To meet the customers needs the Cama packagingline is composed of four in line Triaflex DeltaRobots, which by means of a smart vision systemcan pick loose, naked candies, covered inchocolate, coming randomly from production lineand position them correctly on continuous motionconveyors in a pre-set pattern. Products areselected, according to their dimensions and thenplaced on two external conveyors. The maximuminfeed rate is 360 chocolates per minute (or 200

per lane). Subsequently, the products are wrappedand packaged.

Camas outstanding robotic know-how made it theright choice for the project. We were under a lotof pressure to deliver this project successfully inorder to meet the rapidly growing demand for ourproduct says Aleksey A. Klecov, OzerskyEngineering Manager. Cama was on our side andthe line was delivered within budget, on time andwith a successful vertical start-up.

CAMA USA Inc. 155 N. Pfingsten Rd. Ste#370 Deerfield, IL 60015Phone: 847-607-8797 - Fax: 847-607-8403 [email protected]

4. Focus on materials. Cartoning equipment isrelatively simple machinery; when there is a problem in

cartoning, usually its a material problem. Always remember

that the materials used or cartoning must be harmonized

with the machinery. Understand the material. For reliability,

make sure it is o good grade or quality. Is it virgin boardor recycled material? The answer has a signicant impact

on how the carton is handled. The design o faps and

glue patterns must be considered. You can use less glue

in a stitching pattern. When youre loading a bag into a

carton, the amount o air in the bag has a material impact.

You can use a defator on the ller or a conner on the

cartoner; either way, plan or this ahead o time rather than

discovering the need when the equipment is on the foor.Always test your products and materials at the equipment

vendor (see separate article on actory acceptance testing).

5. Match the equipment to your companystechnical capabilities. Cartoning equipment shouldmatch your companys technical prowess. Acquiring an

overly complex machine could prove problematic. Conduct
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continued


cartoning equipment

www.mgsmachine.com I 800.790.0627

Eliminate yourweb of suppliers

Nothing outsourced.Nothing overlooked.

Everything integrated.

Only MGS has a full range of

product handling equipmentintegrated into our secondary

packaging solutions

Scan here to

Reduce Your Riskon your next packagingequipment investment

a reerence check during your supplier investigation, and

talk to companies comparable to yours to determine i the

equipment you want is something that will per orm to

your specs and be manageable or you. Dierent cartoning

vendors do dierent things really well; make sure you

align their technology with your product, and know thelimitations o any piece o equipment youre thinking o

purchasing.

6. Look closely at the picking mechanism. Thisis oten overlooked. Look at the specic technology used

to pick carton blanks, and look its compatibility with your

particular substrate. I the machine doesnt pick your blank

correctly, nothing else matters.

7. Pay attention to operator ergonomicsand saety. How user-riendly are the controls and userinteraces? How ergonomic is the load/unload stations

where humans are involved?
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continued


cartoning equipment

For denesters,

onserters andhang tag applicators,pick our place.

InnovatIon. Its the name of our game.Our team of experienced design engineers can custom-designconventional and specialty equipment to do just aboutanything. Combine our innovative, sound designs with our24/7-customer support and the result is unmatched service,increased efciency and maximized production fromconcept to completion.

1-888-800-6861

www.graphicpkg.com

Watch demo

8. Dont orget parts. Have as ew change parts aspossible when you go rom one size to the next. (Obviously,

the ability to perorm quick changeovers is a key benet

when using many dierent carton sizes.) Standardizing

with components you already have is much more dicult

or end users than vendors realize (e.g., i youre used tohaving a certain kind o bearing and someone wants to use

a dierent kind o bearing, that can be painul). Keep parts

on hand to acilitate repairs.

9. Be aware o uture needs. Will you need largerpacks or multi-packs in the uture? I the machine only

goes between size A and size B, you may need dierent

equipment. Retrotting can be prohibitively costly. Plan orfexibility and change. Eventually you may need machines

or multiple geometries.
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Ten tips or buying coding/markingequipment or cases and pallets

The handling o case products hasnt changed, but the inormation required on the cases

has. This is driven by documentation concerns (i.e., traceability) and the growing realization

that all space is marketing space; so, cartons once considered dumb carriers are now being

leveraged to display corporate branding. Corrugated cases are moving closer to primary

packaging.

Also, ink-jet technology has improved considerably. Connectivity and ootprints are smaller

and machines are easier to use. There are common touch screen interaces, levels o

control, and higher resolutions. Instead o bottles o ink that you turn upside down, todays

technology eatures sel-sealing cartridges and meters or easy visual checks.

Here are some best practices to ollow and pitalls to avoid when buying coding/marking

technology or cases and pallets:

1. Understand your application ully to reduce costs. Its cheaper to use ink-jetthan it is to use a label, but will your application allow or it alone? Assess the technology in

detail in terms o what youre doing. Research the technical aspects o coding and marking to

ully understand the role o yield, imaging, and perormance to compare models and brands.

Learn how the equipment works; understand what dierent yield and imaging capacities

mean or your specic applications.

By MaRty weil


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2. Ensure that coding quality will meetcustomer needs. Large-character printers may not giveyou the highest quality scannable code. Companies such as

Walmart want better-quality coding on what they call high-

velocity goods, which they process in a highly automated

warehouse. For your product to qualiy as a high-velocitygood, you may nd that print-and-apply technology works

best, but at a higher total cost o ownership including

equipment and consumables (labels and ink).

3. Understand the impact o productdistribution. Rerigerated items will go through reezersand rerigerators. Be aware o where they sit at ambient

temperatures, where condensation is a risk. I the ink andglue on the label arent designed or your distribution cycle,

the label will likely be compromised and can even all o.

Your distribution process may move through dierent

environments, so consider how they will challenge the

packaging materials used.

continued

Ten tips or buying coding/marking

equipment or cases and pallets

High Resolution InkJet Printing

800-369-5384 www.foxjet.com youtube.com/itwfoxjet

Product Identifcation Solved!
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4. Assess impact o recycled content. Corrugatedcases come with increasingly higher recycled content,

which can impact label appearance, label adherence,

and printing. The higher the recycled content, the darker

the box, so with the higher amount o recycled content.

Sometimes it is necessary to print a light backgroundbeore applying a bar code to a case to obtain a unctional

contrast.

5. Closely track database activity. Databaseintegration ensures that coding on the cases ties into the

package itsel. Handling hasnt really changed, but the

inormation you want on the cases has. For example, the

Produce Traceability Initiative (PTI) is only a guideline; howyou implement it depends on your customer. I youre doing

barcodes, the most important thing is that you have a good,

scannable image. Know your customers, as they will drive

the standards youll have to meet.

continued


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6. Be ready or changes. The packaging landscapeis increasingly fuid. Retailers such as Costco and Sams

Club are driving a trend toward shel-ready cases. More

companies are conscious that packaging space has

become a branding and messaging opportunity. Due to the

economic climate o the past ew years, anything to get themessage out rules. Cases o corrugated used to be generic;

in some instances, its moving closer to primary packaging.

7. Consider more than price. Besides cost, a hosto actors need to be considered beore buying coding and

marking equipment, including the equipments history

o use in applications similar to yours. Buying because a

system or machine is on clearance, or is the highest pricedso it must be the best, is shortsighted, as is thinking

that the mid-priced item is most sensible. Exercising due

diligence is essential to successul equipment specication.

Contact customer reerences who have purchased and use

the equipment in a similar setting to obtain eedback on

perormance and reliability.

continued


equipment or cases and palletsD-Series Laser Coders

Think small.

Everybody increasingly needs to do morewith less.

For the new D-Series scribing lasers, small

means more exible.

The new i-Tech scan head is beautifullycompact and ts where larger ones cannot.

The multi-position head makes it mucheasier to adapt to your production linefrom any angle, even in the most restricted

of spaces.

Modular construction includes an optionof standard or IP65 casings, and makes the

D-Series lasers footprint smaller overall.

Altogether a more compact industrial design(and 20% lighter) the new, smaller D-Seriesis a big improvement all round.

Domino. Do more.www.domino-na.com

1.800.486.7414

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8. Avoid generic equipment. Generic codingand marking equipment typically suits businesses with

very basic needs. Do you need more unique solutions or

customizable, robust unctionality? Opt or an equipment

provider that can grow and adapt as your companys vision

and objectives evolve in response to the market.

9. Dont orget maintenance and repair. Digdeep to ully understand the equipment reliability. Again,

reach out to current users o the equipment to gain insight

into daily maintenance as well as the foor perspective.Ask

about operating costs related to the lie o the machine in

terms o ink, maintenance requency, and the cost o repairs

and parts replacement. You may think the upront cost isthe biggest actor; however, the lietime costs can put a big

dent in the budget and aect the supply chain relative to

production schedules.

continued



What does uninterruptedefciency look like to you?

The Videojet 2300 Series redefnes cost-efcient production.

These large character ink jet printers deliver consistent, high-resolution

variable data coding, eliminating the need or preprinted cartons

or labels. So you can maximize productivity and space-savings

while reducing inventory costs. The automatic micropurge o

the printhead ensures sharp image quality, case ater case,

even in dusty environments. The 2300 Series even recycles

ink used or the printheads micropurge to keep your ink drops

where you want it: on your packaging.

See or yoursel what uninterrupted efciency looks like.

Visit www.videojet.com/2300 or call 866-871-3226

Count on the Videojet 2300 Series of Case Coders to deliver it.

Ink Jet. Laser. Thermal Transer. Labelers. Track & Trace. Supplies. Parts & Service.

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10. Consider online case printing. Instead ohousing pallets o pre-printed cases, consider moving to

generic cases that can be printed online and labeled or any

SKU. This creates a tremendous reduction in inventory. The

print quality o digital and on-line case printing systems

have improved considerably, making this an option wellworth exploring.

continued



I asked my box guyabout savings...

Iconotechthe only name

in Generic Case Printing

Saving money is no laughing matter. Printing

plates allow your corrugated supplier to hold you

hostage and all your purchasing power goes out

the window. Generic Case Printing and Iconotech

will give you back the control you need to succeed.

Buying more quantity of less generic inventory,

printing in-house and just-in-time can save you

hundreds of thousands of dollars annually.

Iconotech www. iconotech.com 800.521.0194

He laughed,

I called Iconotech

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Trends in case packing equipment

There are a number o trends that are driving the design o modern case-packing equipment:

1. Retail-ready case packing. Originally driven by club stores, secondary packagingthat can be deployed right on the retail foor with attractive graphics and tear-away sections

or panels has probably been one o the biggest developments in secondary packaging in

recent years. The latest challenge is to be able to produce smaller-count cases at higher

speeds to maintain processing speeds. Also, using shel packages with visible product (suchas windows or exposed carton corners) requires automated machinery that minimizes surge

pressure during packaging. The kind o vacuum used to pick a case up really matters now.

Machines cannot mark, mar, or damage thecases in any way, because theyre being used as

displays now.

2. Lightweighting. Partly or sustainability reasons but also or cost savings, packagersare seeking to use thinner bags, thinner corrugated board, and thinner cartons. Machines

have been redesigned accordingly, handling product a lot more gingerly than they used to,

but still at high speeds.End-o-line packaging machines used to be typically xed-automation

machines. But now, to handle the prolieration o container shapes, sizes, and lighter weights,

whats required is more low-pressure conveyance, more customization, servos, and more

robotics. Robotics can be more ecient at handling lighter weight packaging because o the

amount o pressure and stress put on containers can be more tightly controlled. Pick-and-

place robots might be less likely to cause package damage versus more conventional xed-

automation and drop-pack systems.

By BRian kelly

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3. Increased recycled content cases.Previously,case packers handled virgin corrugated board all the time.

As packers are now seeing a lot more recycled content, it

means that machines have had to be more orgiving and

provide or more tolerance o variation in the quality o the

cases and trays. Equipment really has to be less sensitive

and more tolerant, as variations are appearing on a more

requent basis. Recycled corrugated board also shows

more variation in how it reacts to the environment than

virgin board. Humid or cold environments add to the need

to build more tolerant machines. Vendors see this as an

opportunity to dierentiate, showing that they can handle

these variations. This leads to design changes, dierent

engineering, or reengineering: more use o high-strength,

lightweight materials in machines now, such as carbonber or end-o-arm tools, lighter-weight metals and other

advances in control and precision.

continued


Weve got you covered, with quality,innovation, and service:

Proven performance

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Expert installation

24/7 support, Factory parts

PMMI-certified trainers

Upgrade/refurbish service

For over 73 years, weve been helping our customersprofitably reach their production goals.

How may we help you?

www.abcpackaging.com

800-237-5975

811 Live Oak St., Tarpon Springs, FL 34689727-937-5144 - Fax: 727-938-1239

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4. Machines that accommodate packagingvariety. Marketing requirements are pushing the use oso many dierent packages that suppliers must be able to

deliver case packers that can, with just a ew change parts,

switly change over and accommodate the larger variety

o case sizes and ormats.The challenges are to convey,

accumulate, carton, case and/or wrap these packages at

high speeds, while keeping them well protected, and to be

able to rapidly changeover to dierent package types, pack

congurations, or various rainbow pack combinations

(or example, on-the-spot changeover o favor selections

in a multi-pack o beverage bottles). The increasing use

o servo technology is permitting this fexibility. Quicker

changeovers are driven by the desire to oer greater

customer choice to address occasion-based marketingthe right product in the right package at the right time and

place. Occasion-based marketing depends on the ability to

produce multiple packaging ormats or venues as diverse

as hotel chains, restaurants, club stores, and convenience

stores. Machinery users want to be able to run all these

diverse ormats on the same equipment.

continued

Trends in case packing equipmentS-T-R-E-T-C-Hyour adhesive

Dont let adhesive availability and risingprices slow you down. While otherslag behind, your packaging lines can

be running at faster speeds, using lessadhesive and saving you money.

Like the highway lines in the photo,youll replace long, continuous adhesivebeads with modulated intermittent beadsto optimize adhesive. You can save up to50 percent on adhesive while maintainingbonding and package integrity.

Avoid uncertainty and stay on the roadto success with OptiBond Solutions.

Call Nordson today at 800-683-2314 or

visit nordson.com/OptiBondSolutions

to learn more.

Get more mileage from your

adhesive. Let Nordson OptiBond

solutions help you spend more

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5. Adhesive advances. Manuacturers o adhesiveand adhesive applicator equipment have not stood idly

by either, introducing innovations such as non-heated

adhesive application systems that deliver a oamed

adhesive with rapid set properties. Advantages including

up to 50% less adhesive use than conventional systems,

room temperature pumping and fowing o adhesive that

eliminates the need or heated tanks and hoses, increasing

saety. Also, newer hot melt ast set adhesives are debuting,

eliminating the need or excessive heating and hot system

engineering, resulting in savings opportunities on wear

parts and maintenance because o the reduction in heated

components.

6. More integration. Packagers are pushing ormore integration in their lines; instead o buying discretepieces o machinery and cobbling them together, they

really are requiring that OEMs integrate complete end

o line solutions that achieve the desired output or the

continued


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entire line. Packagers want machines that can be able to

communicate with each other; theyre looking at the lines

holistically. They want the HMIs to have a similar look and

eel, more standardization o components, and theyre

speciying standardization o pumps and controls, and

are beginning to adopt PackML to streamline integration

between machines. A common platorm also makes it

easier or packagers to train their operators. In short,

whats driving case packing design is packagers need to

make the equipment easier to use, more accessible or less

experienced operators, simpler, aster changeover, and

greater fexibility because packaging styles change at an

unprecedented rate.

continued


FOCKE & COGeneral PackagingIndustriestrae 1726676 Barel GermanyPhone: +49 4499 [email protected] www.focke.com

FOCKE & CONorth America5730 Millstream Rd.Whitsett NC 27377Phone: +1 336 [email protected] www.focke.com

TOMORROWSTECHNOLOGY TODAY

As one of the worlds leadingmanufacturers of packaging

machines, FOCKE & CO is aprivately held company with over16.000 installed machinesworldwide and more than 50years of experience.

Highly Flexible Packer ability to load mixed

orientations gentle product handling wide variety of product sizes

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Checklist or buyingcase packing equipment

When you approach case packer manuacturers, its best to have a document prepared that

answers all o the ollowing questions:

1. Product and package. What is your product? What is the package type (e.g., carton,

tub, bottle, can, blister pack, etc.). Does this product have dierent sizes that you wanthandled on a single machine?

2. What are the dimensions o the primary package? Youll want to speciydiameter and height, i a round container. Or length, width and depth (LxWxD) i a carton.

Most case packer manuacturers will want LxWxD according to how the product will be

placed in the container relative to the container opening.

3. How will the product be delivered to the machine? Will the package bestanding up? Laying on its side? Entering the machine acing which way? Sometimes drawing

a little sketch showing how the package will be oriented on the ineed conveyor will help.

Also, what do you want to see when you open the case? How should the package printing or

labels be acing?

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4. Line speed. How ast will containers be coming intothe case packer, in packages per minute?

5. Case count and pack pattern. How manyproduct packages will go into each size container? What

are your desired pack patterns? This can be communicatedby indicating the pack count along each dimension. For

example, 24-count 3x4x2 (LxWxD) means there are three

products along the longest fap (width dimension), 4

products along the shortest fap (width dimension), and 2

layers o product (stacked 2 high) in the depth dimension).

6. Weight/handling issues. Is your product very

heavy or very light? Wet, sticky, or slippery? Hard or sot?Hot, cold or rozen? Sturdy or wobbly? Liquid or solid? What

is the room temperature and humidity level where the

machine will run?

continued

Checklist or buying

case packing equipment

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7. What conguration are you looking or?Semi- or ully automatic? Wrap-around, horizontal, top or

bottom load? Let or right hand? Inline, perpendicular, or

counterfow? Glue (hot or cold) and/or tape sealing? Do

you have a controller preerence or special electrical or

automation standards?

This article was excerpted from a handbook from Schneider

Packaging Equipment Co., Inc.

continued

Checklist or buying


We Provide

Complete

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BluePrint Automation is a world leader in packaging automation. Ourmission is to deliver solutions that oer true fexibility in real worldproduction environments.

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[email protected](804) 520-5400

Vision-Guided Robotics Case/Tray Packing

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Best practices or selectingcase packing equipment

Here are a ew things to look out or when selecting case packing equipment:

1. Know your product loading orientation.There are top loading, side loadingor end loading congurations available in case packing equipment.You can save a lot o

time and energy in selecting vendors and equipment i you know in advance just what theappropriate loading orientation is or your needs. Design in reliability. Ask yoursel i your

loading orientation can change to allow or enhanced reliability.

2. Look into how the case packer reacts to variances in materials. Tryto talk to other customers to nd out how the case packer responds when a lower quality,

damaged, or soggy (in humid conditions) piece o corrugated board is ed into it.

3. Ask other users about accessibility. When youre talking to customer reerences,ask whether their operators and technicians can you get into the machine to clean it. Is the

door accessible to the operators? Are guides and hold-downs too heavy to lit, or are they

ergonomic and user riendly? Can operators open and close the doors? Is it easy to replenish

the machine with blanks?

By BRian kelly



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4. Dont ignore a machines ability andmethod or case squaring.The squareness othe case is critical or proper conveying and palletizing

downstream. As simple case squaring guides can also

cause the case to drag back and skew, consider positively

actuated case squaring. Accurate timing and positioncontrol are needed. A test with your actual appropriately

packaged product samples is best.

5. Find out what happens when you changesizes.Some packagers have to change a lot o sizes, andsome case packers require a lot o changes to do so. Is

the entire machine servo controlled? Is it all mechanical

adjustments? Are the size change controls and dialsaccessible and easy to operate? How oten will you be

changing over, now and in the uture? Customers are

demanding more customization, so be sure you select a

case packer that allows your operation to have the fexibility

to meet the uture demands o your customers.

continued

Best practices or selecting

case packing equipmentdeservegreat ideasgreat machines

At Aagard, were committed to providing our

customers value with end-of-line automated systems

that redefine the standard. Our simple, clean, integrated

systems have made us leaders in the packagingindustry, and were ready to provide your

company the competitive advantage with our

Combination Cartoner and Case Packer Systems.

3711 Iowa Street | Alexandria, MN 56308 | 320.763.6043 | www.aagard.com

Visit www.aagard.com and see how the Aagard

Advantage can become your advantage.

REDEFINING THE STANDARD

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6. Product control in case packing is o vitalimportance.The ability o a case packer to handle andmanage ineed pressure is key. You may be able to eed 100

eet o product, but i the case packer cant handle it, its bad

line design.Ater primary packaging, secondary packaging

can seem slow. Yet, incoming product speeds, linearspeeds, and cycle velocities are high. Avoid accepting low-

technology drives or actuators (air cylinders or example)

without closely evaluating whether the lack o velocity and

position control will cause eciency issues. A simple air

cylinder to tuck a case fap may seem adequate but as time

wears on, does it perorm the same or could its velocity and

motion change, causing jams? I a machine does jam, can

the actuator properly recover?

7. Re-consider case counts. Give thought to whatkind o case counts will work best or the case packer and

packaging line you are considering. For example, going

rom our cartons to ve cartons in a case will slow output

by 20%. That may be the dierence between running well

and not running well. Having said that, fexibilty in case

continued



Cooler is

cheaper.You can bank on the rst cool-on-delivery, hot-on-demand adhesive

system. Unlike hot melt with heated

tanks and hoses, Liquamelt means

less mess. Less energy. Less waste.

And less downtime. All of which,

adds up to more savings.

Learn more about how cooler is

cheaper at hbfuller.com/liquamelt

Adhesive System

2012 H.B. Fuller Company

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design necessitates a wide range o operational speeds.

Again, customer requirements or dierentiation in case

counts must be considered or the uture eectiveness o

your purchase.

8. Consider glue versus tape.Tape seals the caseagainst dust but does not necessarily hold the case square

during transporting (especially during palletizing, on

orklits, etc.). Glue seals aster and makes a stronger case.

Hot-melt seals very ast, needing little compression, but

costs more than cold glue or tape and typically needs more

maintenance. Cold glue has a superior bond with adequate

compression time (which typically means a longer machine

that costs more). Combination sealing can be used, such ashot/cold glue or glue/tape combinations.

continued



Cooler issmarter.Graduate to the rst cool-on-delivery,

hot-on-demand adhesive system.

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and hoses, Liquamelt isnt just

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And cheaper. Making it a lot smarter.

Learn more about how cooler

is smarter at hbfuller.com/liquamelt

Adhesive System

2012 H.B. Fuller Company

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Wraparound versus RSC cases

It may be possible to save corrugated costs by switching to wraparound cases rom regular

slotted cases. To calculate potential savings, measure the length, width o each fap and panel

in your existing RSC, and sum the resulting gures. Include the manuacturers joint in your

measurements. Compare the totals or equivalent wraparound style case blanks. There may

be more waste with one wraparound case design than another, so less area alone does not

always mean a cost savings. To be sure, ask your corrugated manuacturer. The square ootage

o the corrugated can be less and the charge or gluing the manuacturers joint is eliminated.

Other benets o wraparound-style cases: A case magazine can hold twice as many

wraparound cases versus a standard RSC style. Also, the wraparound case is strong and oers

a tight product t which increases column strength and pallet eciencies.

Though a well-engineered case packer can be orgiving with badly made cases, its not worth

saving a ew pennies. Invest in quality cases or maximum uptime.

Tip: Ask your corrugated supplier to put a mark along one case old. This mark tells operators

whether a case is in the magazine upside down or backwards. Its a real time saver on a busy

production line.

This article was excerpted from a handbook from Schneider Packaging Equipment Co., Inc.



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Glossary o case packing terms

Bottom Load Machine Product is loaded vertically up through the open faps on thebottom o a case.

Basis Weight Weight o various containers given in pounds per 1,000 sq. t.

Boxmakers Certicate Statement printed on a corrugated or solid breboard box

guaranteeing that all applicable construction requirements o the carriers have been met.Also identies the box maker.

CSO (Center Special Overlap Slotted Container) All faps are the same length;inner faps meet and outer faps overlap at random.

CSSC (Center Special Slotted Container) Inner and outer faps meet at center.

Containerboard The paperboard components (lineboard, corrugating material, llerchip) where corrugated and solid breboard is manuactured.

Corrugated Board Board consisting o two outer plies that sandwich a futed middle layer.

Cycle Process by which product package or container moves rom station to station inaccumulator or main machine. (see Station or Pockets)

This glossary was adapted

rom a handbook by

Schneider Packaging Equipment.



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continued


Double Wall A combination o three fat acings andtwo intermediate corrugated parts.

Enclosure Types Electrical connection protectionlevel or the operating environment (see the basic NEMA

ratings page 39):

Facings A orm o linerboard used as fat members ocorrugated breboard.

Fibre or Fibreboard Box A container madeo either corrugated or solid breboard; breboard is

abricated paperboard (three or more plies o walls).

Flute or Corrugation One o the wave shapes in the

inner part o combined corrugated breboard.

Flutes perlinear oot

Approximate height(not including acing thickness)

A-fute 33+3 3/16 inch

B-fute 47+3 3/32 inch

C-fute 39+ 9/64 inch

E-fute 90+4 3/64 inch

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continued


FOL (Full overlap Slotted Container) All fapssame length; outer faps overlap not less than inside width

o box minus a maximum o one inch.

Hal-Slotted Case An RSC style with bottom faps andno top faps.

Hand, machine Let-hand machine meansaccumulator is on let side o main machine when looking

in the fow direction and conveyor is on right side o main

machine discharge.

Horizontal machine Product is loaded (horizontallypushed) into the side or end o a carton, case or tray.

Inline machine Main machine is placed lengthwise inthe same direction as the conveyor delivering product.

Knocked-Down (KD) A term denoting that a carton,case, or tray is partly or entirely taken apart; not setup.

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continued


Liner (Sleeve) A creased breboard sheet inserted in acontainer and covering all side walls.

Manuacturers Joint The joint is that part o thebox where the ends o the scored and slotted blank are

joined by tapping, stitching, or gluing. When nished in the

box manuacturers plant, it is known as a manuacturers

joint; when the box faps are sealed in a box users plant

(usually on automatic equipment), it is called a users joint.

NEMA Ratings Rating scale or measuring the level oprotection or electrical connections given the operating

environment.

NEMA 1 General purpose; indoor usage; no unusualservice conditions.

NEMA 2 Dripproo; indoor usage; protect against non-corrosive liquids and dirt.

NEMA 3/3R Dustlight; raintight and sleet (ice) resistant;outdoor usage; protects against windblown dust and water.

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NEMA 4 Watertight and dusttight; indoor and outdoor usage; protects against splashingwater, water seepage, alling or hose-directed water, severe external condensation.

NEMA 4X Watertight, dusttight, and corrosion resistant; indoor and outdoor usage; seeNEMA 4 above plus corrosion protection.

NEMA 7/9 Explosion resistant; indoor hazardous locations; airbreak equipment to protectagainst entrance o explosive amounts o hazardous dust.

NEMA 12 Dusttight and driptight; indoor industrial usage; protects against bres, lings,lint, dust, dirt, light splashing or seepage, dripping and external condensation o noncorrosiveliquids.

NEMA 13 Oiltight and dusttight; indoor usage; houses limit switches, oot switches,pushbuttons, selector switches, pilot lights, etc. to protect against lint, dust, seepage, external

condensation, spraying o water, oil or coolant.

Orientation How a product is delivered to an ineed conveyor, discharge conveyor, orloaded into a containere.g. largest dimension perpendicular or parallel to fow; largest

dimension perpendicular or parallel to case length, width, or depth. Product length, width,

and depth are relative to how it loads into the case.

continued

Glossary o case

packing terms



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Overlaps A design eature where the top and/orbottom faps (usually outer only) extend over the other.

Overlap is measured rom fap edge to fap edge and is

known as partial or ull overlapping faps.

Pocket Space reserved in main machine to do one o

the ollowing operations case select, case erect, case old,

case load, case fap tuck, case seal, case seal compress.

Some o these operations can be done in the same

horizontal space under certain conditions (slow speed,

small product, smaller ootprint needed). Product is passed

rom one pocket to another by pushers.

RSC (Regular Slotted Container) All faps samelength; outer faps meet.

Single Face A combination o one corrugated partglued to one fat acing.

continued


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Single Wall Also known as Double Face. A combinationo one corrugated inner part glued between two fat acings.

Standard Test Conditions Tests on paperboardand boxes are normally done at 73 degrees F and 50% RH +

or 2.5%; High humidity is temperatures above 73 degrees F at

85% RH; Cold storage is below 40 degrees F at 85% RH; Tropical

storage is above 90% degrees F at 90% RH.

Station Divisions within the main machine thatmechanically perorm unctions necessary to erect, old,

load, tuck, glue or tape, and seal a container. These stations

can be combined under certain circumstances into multi

purpose units. (see Pockets)

Test Bursting strength o linerboard and combined boardexcept or those grades o corrugated breboard where a

puncture test is substituted or bursting strength. There are

many kinds o tests done depending on environment.

continued


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Nine tips or selecting multipackingand shrink bundling equipment

In todays multipacking and shrink bundling environment, the need or fexibility and

precisely repeatable changeovers is taking precedence. This is driving equipment design,

even on highly complex equipment. It is also infuencing the dumbing down o machines,

specic to changeover and fexibility, where responsibility is taken out o the hands o

operators, or removed entirely. Users are demanding higher overall equipment eectiveness(OEE), longer mean time to ailures, and greater predictability.

Machine builders are adding control with ully integrated robotics instead o integrating with

another machine or added unctionality. Rather than having three axes o linear movement

(e.g., a pusher), the vendor may install a delta or Cartesian robot. Robots are simpler and

cheaper than they used to be, and utilize smaller ootprints.

The prolieration o SKUs and brands has driven down shel space, which in turn has increasedinventory turns and the desire or smaller packages. This need has dramatically increased

bundling speed. The costs o bundling, labeling, and coding have almost doubled due to

sending the same tonnage in smaller bundles!

By MaRty weil

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Here are some tips to consider or those selecting

equipment in this challenging environment:

1. Look to downgauge.The use o polyethyleneand similar thin lms is a huge cost-cutting opportunity.

Fity percent o customers use heavier gauge lm than

they need. Why? A thicker gauge buys a lot o orgiveness,

allowing companies to get away with sloppier setup, less

ecient machines, and less competent operators. Premium

lms are being used to accommodate these shortcomings.

While downgauging involves a lot o work, it can pay o.

Instead o using a lm that costs $4 a pound, you can

use one that costs $0.71 a pound with the right bundling

machine. In act, lm suppliers are producing better-quality,inexpensive thin lms.

2. Identiy the right technology platorm,especially i its a new process or thebusiness. Whether its a wraparound tray, corrugatedpad, or unsupported shrink bundle see what your product

and distribution environment can handle. Rigid containers

continued

Nine tips or selecting multi-packing

and shrink bundling equipment

F O R M I N G L O A D I N G C L O S I N G 800-328-5558 delkorsystems.com

packaging innovation at work.T

ATYOUR COMMAND

CASE PACKING WITH RETAIL READY

Delkors Case Packing solutions provide unique fexibility.With todays rapidly changing retail environment one cannot afford to havea packaging line that only produces one package style. A Delkor case packeris designed with the versatility to run a variety of package formats, includingRetail Ready . . . all with tool-less changeover.

We engineer our machines to protect your investment.

To see it in action, visitdelkorsystems.com/retail-ready-packaging.html

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such as metal cans easily transition rom a tray to a pad. But

what i youre dealing with a 3-ounce plastic bottle with an

hourglass shape? Be very careul and do a lot o testing to

see i its even possible to move rom a tray to a pad to an

overwrap. Shrink-only packs will obviously save corrugated

costs, but such a move requires oresight and planning

to ensure package integrity with package development

experts.

3. Speed matters.The speed at which youre packingor bundling is a key parameter. The number o products

on a pad or shrink bundled remains on the upside o the

growth curve. Consider this as you examine potential

equipment. While there are no hard and ast rules, theimpact o product development on bundling speed cannot

be ignored.

4. Size matters as well. Pay attention to the lengtho the shrink tunnel. Dont undersize it. Film takes a certain

amount o time to heat up and shrink. Selecting shorter

heat tunnels with higher heats is not good logic. For higher

continued

Nine tips or selecting multi-packing

and shrink bundling equipment

The EM series o machines rom Optima Machinery Corporation are

designed as ully automatic, in-line, robust systems. The EM utilizes

an integrated stacking unit to create side-by-side, double, or quad

ormations. The EM oers the unique capability to automatically pull

the required flm to match the circumerence o the bundle. Thereo-

re, making it possible to run and create side-by-side, double, or quad

bundles sequentially.

Grouping and

Bundling.

EXCELLENCE IN PACKAGING

OPTIMA

20 Product/ min. Input 5-10 Bundles/ min. Output

OPTIMA Machinery Corporation | 1330 Contract Drive | Green Bay | WI 54304-0173 | USA

Phone +1 920 339-2222 | Fax +1 920 339-2233 | E-Mail [email protected] | www.optima-usa.com

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playbook endofline v9 opt

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