the most innovative machines - rockwell...

The most innovative machines with Rockwell Automation solutions

21851 Booklet Cover A4 AW V2.indd 1 07/04/2014 15:30

Table of Contents

Company Country Page

ARP France 3

Cama Italy 5

Ilapak Switzerland 7

Karlville France 9

PDC France 11

Record Italy 13

Sleever France 15

Somtas Turkey 17

Tecmapack France 19

Tosa Italy 21

Twin pack Italy 23

Solutions in Action

ARP, Automation Robotic Packaging, specialises in compact end-of-line machines for overpackaging and casing of food processing products. Since its creation in 2008, the company has developed original compact or bundled solutions. Its solutions are installed in both SMEs and big international food processing groups. Represented in several European countries and the Americas, its customers already include big international companies such as Yoplait, Galette Saint Michel, Fage (USA), Skotidakis (Canada), Babynov (France), Barilla, Fenwal…

The machine presented at the Emballage 2014 show, the CPS-5, is a single-station module that packs in all of the end-of-line functions off ered by ARP machines: bundling of products, box overpackaging, tray forming, casing and stacking of cardboard trays.

All of these functions are controlled from a single workstation, with the operations performed one after another by the same robot.

Every 10 minutes (or on request) at its stand at the Emballage show, the CPS-5 will carry out a complete production cycle, executing all the functions mentioned above.

A single-station machine such as the CPS-5 can meet the needs of low-rate lines. Its compactness and quality make for major assets. With this presentation, ARP demonstrates that it is possible with a single machine to meet the expectations of manufacturers in terms of end-of-line overpackaging and casing.

ControlLogix programmable automation controller

Kinetix 5500 axis control cards

The CPS-5 is equipped with a comprehensive latest-generation Rockwell Automation solution, based on a single EtherNet/IP network.

AUTOMATION ROBOTIC PACKAGINGA NUTOMATIONAA ROBOTICRR PACKAGIN

The CPS-5 is equipped with a comprehensive latest-generation Rockwell Automation solution, based on a single EtherNet/IP network. This solution includes: a ControlLogix programmable automation controller, Kinetix 5500 axis control cards; a Stratix 5700 switch for managing the EtherNet/IP network which connects all the equipment and provides the communications; Point I/O on/off inputs-outputs and a PanelView 1500 display terminal.

For ARP, many of whose customers have an international presence, Rockwell Automation solutions was the essential choice, both in terms of product performance and the training resources and worldwide services its customers require.

For more information, contact: ARP Pascal PORTRAIT, Manager Phone: +33 (0)2 54 29 68 20 E-mail: [email protected] www.arp360.com

Allen-Bradley, ControlLogix, Kinetix, LISTEN. THINK. SOLVE., PowerFlex, PanelView Plus, Rockwell Automation and Stratix 5700 are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVATrademarks not belonging to Rockwell Automation are property of their respective companies.

Publication OEM-AP408A-EN-P – October 2014 Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.

Solutions in Action

Cama Group is headquartered in Garbagnate Monastero (Lecco), in Northern Italy, and has subsidiaries in France, United Kingdom, Germany, Thailand, United States, China and Australia. The Italian company is known globally for the cutting edge technology and the reliability of its packaging systems.

The packaging machines and robotized lines designed, manufactured and installed by Cama worldwide, can be used in the food and non-food industry and cover the whole primary and secondary packaging processes, from the line entrance to the end-of-line packaging operations, before palletising.

Cama’s IF315 is a compact machine, which includes a compact former, a loading system with delta robot (RB590) and a closing system with a two interpolated axis robot (MN530) with a specific lidding tool. “The machine is set up for the secondary packaging of flow-packed snacks bars, but it can be adapted to pack other kinds of products and can be easily integrated in a packaging line just before the palletising station,” Riccardo Panepinto, Director of Operations at Cama, says.

The machine has been built by Cama according to its new cabinet-free design concept: actually, the IF315 belongs to the Cama Break-Through Generation series, which stands out for its reduced footprint obtained by integrating the electrical and pneumatic components control cabinets into the machine pedestals angles.

Allen Bradley 1756-L72S GuardLogix controller

The Allen-Bradley Kinetix 5500 servo drive family

The IF315 has been built by Cama according to its new cabinet-free design concept

Such compactness helps to minimize cabling and makes it easier to place the utility devices right where they are needed, with further benefits in terms of accessibility for maintenance tasks. As Mr Panepinto states: “These new machines have a so-called ‘no hollow-body’ structure, that means that there are no closed or hard to be reached cavities on them, as their frames have open or opening parts”.

The forming station on the IF315 is characterised by the reduced height of the carton blank magazine, which is about 750 mm high, while the standard height is more than 1,200 mm.

The carton blank is picked up and positioned in the forming station by a Kinematic system, which uses a single motor, whereas standard systems usually have two. Once the box is formed, it is placed on a positive conveyor belt, which is synchronized with the product-loading and box-closing phases.

A delta robot (RB590), with a suction head, picks the products from the multiple-pocket conveyor and places them into a single box. Once the loading phase is completed, the box is moved to the closing station, where a two-interpolated-axis robot (MN530) translates and closes it (pressing the glue).

Compactness and reduced changeover time, both on the former and the robots, where parameters can be reset in a few minutes, are the main features of the IF315. Its reduced footprint doesn’t compromise its performance, as it can package up to 600 products per minute. Last but not least, there is no need for large areas to install more than one machine, as they can be placed next to one another, even in reduced spaces.

The automation system on the IF315 has been designed and built using Rockwell Automation® components, which fit Cama’s needs when it comes to developing integrated automation and complex control applications. “Our main goal is to optimize the software engineering for a better impact on energy savings; for example switching off the conveyors (motors) on the machine when the process is in stand-by due to products starving (upstream) or due to equipment stopping (downstream),” Mr Panepinto adds.

An Allen Bradley® 1756-L72S GuardLogix® controller manages the machine’s functions by synchronizing the three phases of the packaging process. Thanks to the GuardLogix Integrated Safety System, the IF315 complies with Performance Level D and Category 3 safety design, accordingly to the latest EN 13849-1.

Using the RSLogix™ 5000 programming software, Cama configured a ten axis motion system, managed by Allen-Bradley Kinetix® 5500 drives. Synchronization among the drives has been programmed using a virtual axis master.

An Allen-Bradley PanelView™ 1000 Plus operator panel has been selected for visualization tasks, and is configured through FactoryTalk™ View Studio V7 software.

Flexible I/O and EtherNet/IP connectivity complete the automation architecture on the machine.

When it comes to defining the benefits Cama obtained by using Rockwell Automation components, Riccardo Panepinto has no doubts in saying that they helped to minimize wiring and troubleshooting operation, while making testing and validation easier.

“In addition to reduce the changeover time, we also have to mention an improved man and machine safety, reduced floor space and a shorter time needed for the machine installation and start-up,” Mr Panepinto explains. Other important advantages can be listed again in terms of energy savings: “We selected Rockwell Automation contactors with low-consumption coils, Allen-Bradley MP-Series™ low-inertia single cable motors and distributed I/O in order to save as much energy as possible,” he concludes.

For more information, contact: Cama Group Riccardo Panepinto, Operations Director Phone: +39 031 879811 Fax: +39 031 856373 E-mail: [email protected] www.camagroup.com

Allen-Bradley, FactoryTalk View, GuardLogix, Listen. Think. Solve., PanelView and RSLogix 5000 and are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.


Solutions in Action

Ilapak – Ilapak story dates back more than 40 years. Founded in 1970, the company manufactures and sells industrial wrapping machinery for primary packaging, utilizing flexible wrapping materials.

Ilapak’s offering includes HFFS (Horizontal Form Fill Seal) and VFFS (Vertical Form Fill Seal) machines, weighers, dosing units for vertical solutions and complete automatic packaging lines, conceived to cover primary and secondary packaging processes.

Headquartered in Lugano (Switzerland), Ilapak is present in 50 countries through sixteen sales and service subsidiaries and a significant number of qualified agents. The company delivers more than 600 machines per year and has several production sites too: in Lugano (Switzerland) they specialize in HFFS machines; in Arezzo (Italy), they produce VFFS machines, weighers and dosing units; in Rogers (Arkansas) they manufacture HFFS and end-of-line solutions, leveraging on the competence provided by Delta Systems, a company acquired by Ilapak in 2008 and focused on HFFS machines for bakery and biscuits too. Another manufacturing site is in Charlotte (North Carolina), while in Lang Fang (China), Ilapak manufactures both VFFS and HFFS entry-level machines for local markets.

Food industry is the first industrial segment Ilapak machines are addressed to. “We have a know-how in bakery, biscuits, cheese, chocolate and confectionary, meat and poultry, vegetables and fruits, IQF (Individual-Quick-Freezing) and pizza & tortillas”, Christian Romualdi, Marketing Manager at Ilapak, says. “We also deal with coffee and tea, snacks, fish and

Allen-Bradley Kinetix 6500 servo drive

Allen-Bradley CompactLogix programmable automation controller (PAC)

seafood packaging, as well as with some non-food products: wet wipes, medical devices and pet food are some of them”.

Such a wide supply allows Ilapak to serve a large base of customers. Big international companies as well as small and medium businesses turn to Ilapak to develop their packaging applications and they both find solutions which can meet their needs.

In addition to its wide range, there is another key factor, which makes Ilapak a point of reference in the packaging world. As Mr Romualdi goes on: “We’ve always been committed in promoting our best-in-class support and its reliability towards our customers and prospects; the company itself was founded following the idea that we have to work with the customer at each step of the packaging machine manufacturing process, from engineering, through product customisation, to line set up and integration, post-sale and spare parts service”.

Ilapak welcomes on stage its Vegatronic 6000, a vertical packaging machine, fully equipped with Rockwell Automation control, motion and visualization solutions. The Vegatronic 6000 is a high-performance continuous film motion machine, which Ilapak introduces as a top solution among the ones included in its high-end range of machines.

“The machine features an innovative system to run quad bags and Doy-style pouches at high speed in a very user-friendly execution,” Romualdi says.

The new Vegatronic 6000 machine is a very versatile solution for a wide range of products (both wet and dry) and pack styles.

The control core of the Vegatronic 6000 is a CompactLogix® L33 PAC, which manages an 8 axes motion system based on Kinetix® 6500 servo-drives. Thanks to this solution, the control application features an easy-to-use environment and leverages on a tight integration between the programming software, the controller and the I/O modules. At the same time, the single controller integrates motion and drives functionalities.

For the human machine interface and the visualization, Ilapak selected a PanelView™ Plus 700 graphic terminal.

“We have been working with Rockwell Automation since twenty years and we know the quality of their technical support and the peerless technological content of their solutions very well”, Romualdi says.

By integrating Rockwell Automation solutions on the Vegatronic 6000, Ilapak engineers could develop the control application more quickly: “Sure, we could save design time and reduce our programming efforts, as our guys are very familiar with the common programming environment provided by the Rockwell Automation Integrated Platform”, Romualdi says. Among the other benefits achieved by Ilapak, there are a minimized wiring, a better troubleshooting and easier testing and validation.

Ilapak purchased the components and implemented them on the machine. “We think that Rockwell Automation technology can be the best choice for those customers who demand for medium/top level automation components”, Romualdi explains, pointing out that the brand is in fact recognized as a standard by Ilapak’s American customers.

For more information, contact: Christian Romualdi Marketing Manager, Ilapak International Phone: +41 (0) 919605975 E-mail: [email protected] www.ilapak.com

Listen. Think. Solve., Allen-Bradley, CompactLogix, Kinetix and PanelView are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.


Solutions in Action

Based in the city of Vaulx-en-Velin, in France, Karlville Development is part of the Karlville Development Group, a global manufacturer of shrink sleeve converting, pouch converting and narrow web slitting/inspection equipment, which is headquartered in Miami, Florida. Through a recent strategic acquisition policy, the Group has entered the packaging sector increasing its portfolio of packaging equipment for shrink sleeve applications, as well as tape handle and tape bundling applications.

Serving a wide customer base operating in printing and converting industry, Karlville Development is committed in engineering innovative technologies for flexible packaging applications.

One of Karlville Development’s latest innovations is a carryhandle application machine, which is fully equipped with Allen-Bradley® products from Rockwell Automation.

Allen-Bradley CompactLogix programmable automation controller

Karlville Development’s latest innovation is a carryhandle application machine, which is fully equipped with Allen-Bradley products

“Following an earlier implementation of Rockwell Automation products into Karlville’s sleeve application equipment previously, the use of Allen-Bradley products in the CEFMAHANDLE range is a logical next step. Rockwell Automation products and support permit Karlville to provide technical solutions from the R&D phase through the complete product life, including after-sales service in remote and distant sites around the world. In addition, from a sales perspective, the use of Rockwell Automation products is a definite advantage for many large international companies, either line integrators or bottling companies for top tier labels,” explains Karlville Commercial Director William Gwynn.

In order to combine reliability with efficiency on the same machine, with compact functionalities at affordable costs for markets such as the Western European ones, Karlville Development selected an automation platform based on the Logix family from Rockwell Automation. “We decided to use an Allen-Bradley CompactLogix™ programmable automation controller (PAC), with motion control capabilities, which is directly connected to Allen-Bradley Kinetix® 6000 servo drives, Allen-Bradley MPL Series synchronous motors driving the axes, rack-mounted I/O and an Allen-Bradley PanelView™ Plus 700 HMI,” M. Gwynn explains.

Thanks to this configuration, the new Karlville Development machine offers end-users a compact and cost effective, yet flexible and high-performing solution for carryhandle applications. The Integrated Architecture concept offered by the Logix platform gives both the Karlville Development engineering team and its final customers the chance to share the same programming language for all sequential and motion control parts – relying on a unique database for the PAC and the HMI and on a unique connection for remote access. This integrated automation solution helps end-users, who choose new machine from Karlville Development, to reach the highest level of automation and drastically reduce machine downtime.

M. Gwynn also says that Karville decided to turn to Rockwell Automation mainly because it needed a partner that could give it qualified support, both in the Research & Development phase and in pre- and after-sales services. “We know our Western European customers’ needs very well and we want to supply them with high-skilled customer support and qualified after-sales assistance, as well as with best-in-class automation.”

Karlville Development know that service is just as important as product quality to end-users and that efficient customer service is a must, especially in the case of machine downtimes and failures, which rely on component replacement in a very short time. As a global supplier Rockwell Automation was able to help the French company in reaching its goal. Rockwell Automation cooperated with Karlville Development both in France, where the new solution has been manufactured, and in the Americas, where it was delivered.

For more information, contact: William Gwynn, Directeur Commercial Karlville Development Phone: +33 0472 812 929 Fax: +33 0472 812 928 E-mail: [email protected] www.karlville.com

Allen-Bradley, CompactLogix, Kinetix, LISTEN. THINK. SOLVE., PanelView Plus and Rockwell Automation are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.


Solutions in Action

Specialising in the field of sleeves since 1984, PDC is a French family company whose head office is based in Montdidier, in the Somme region. The company designs and manufactures machines for fitting stretching and shrinking sleeves, and installs them throughout the world. Its range of sleeve applicators is the widest on the market. Its machines cover a host of applications: simple or complex-shaped product decoration, tamper resistance, bundling, etc.

PDC serves international customers from a wide variety of sectors: food processing (60% of its revenue is made in the beverages sector…), body and domestic hygiene, parapharmaceuticals and cosmetics, consumer goods (batteries, pens, lighters, etc.).

The machine can apply shrink sleeves (which hug the contours of the product under the action of heat) or stretch sleeves (which hug the contours of the product thanks to their elasticity).

Working principle: after winding out a coil of tubular wire (sleeve), the machine positions the sleeve on a mounting head. Two stretch support carriages then pick up the open sleeve and mount it on the product. “This machine, in its standard configuration, is the most flexible we have to date, in terms of sleeved product dimensions,” notes Derek Vandevoorde, Chairman of PDC Europe.

Allen-Bradley Kinetix 5500

Allen-Bradley ControlLogix

The STA-BM is used at the start or end of the line, depending on the product to be processed.

The STA-BM is used at the start or end of the line, depending on the product to be processed (empty or full product).

Every movement of the STA-BM is programmed specifically for the product to be sleeved. Capable of optimising its movements to sleeve a product at a given rate, and of optimising them for a higher speed, the machine runs on a “just enough” basis, as D. Vandevoorde puts it. Depending on the type of product to be sleeved, the appropriate procedure and associated control program are selected via a human-machine interface (HMI).

“The STA is a universal machine designed for the products of both today and tomorrow,” specifies Mr Vandevoorde. “It can perform sleeving applications for all products”. The flexibility of the machine relates both to the applications (type of product to be sleeved, whether buckets, bottles, pens, lighters, etc.) and the technologies used (stretch or shrink sleeve).

The machine is controlled by a Rockwell Automation system comprising an Allen-Bradley CompactLogix or ControlLogix programmable automation controller, a PanelView Plus 6 human-machine interface, Kinetix 5500 axis controllers and VPL servomotors, all communicating via EtherNet/IP.

PDC exports the majority of its machines, and its customers are mostly based in the United States and Northern Europe: geographic zones where Rockwell Automation solutions are popular among users.

“It was important for us to become experts in Rockwell Automation technology, to achieve optimum operational smoothness for ourselves and our customers,” explains Derek Vandevoorde.

“Rockwell Automation’s strategy and range are well-suited to the expectations of the market, both for machine manufacturers and their customers. And the quality/price ratio of its solutions is appreciated.”

The Rockwell Automation solution installed on the STA-BM has enabled all operations to be automated: format changes and adjustments to the machine’s mechanical components are all controlled from the existing human-machine interface.

The design of the machine means that a very wide range of products can be sleeved. Which makes it a lasting solution with an excellent ROI. “The customer who purchases a machine today knows that tomorrow they will be able to keep step with developments on their market, without modifications,” concludes D. Vandevoorde.

For more information, contact: PDC Europe Phone: +33 (0)3 22 78 93 15 Fax: +33 (0)3 22 78 83 83 E-mail: [email protected] www.pdceurope.com

Allen-Bradley, ControlLogix, CompactLogix, Kinetix, LISTEN. THINK. SOLVE., PanelView Plus and Rockwell Automation are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVATrademarks not belonging to Rockwell Automation are property of their respective companies.

Publication OEM-AP402A-FR-P – October 2014 Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.

Solutions in Action

Record’s history began in 1965, when Giuseppe Fioravanti founded the company, starting on small-scale production of flow-pack machines for food and non-food products. In the following years the demand for packaging solutions was expanding and Record succeeded in the market thanks to its winning vision of increasing the flexibility of the then rigid flow-packing systems.

Headquartered in Garbagnate Monastero, in the province of Lecco, in Northern Italy, the company designs and builds horizontal form fill seal machines (HFFS), automatic feeders and packaging systems.

“Our machines are designed to provide customers with safety and continuity, high-speed output and quality,” Ivo Galimberti, Sales & Marketing Manager at Record, explains. The company is well known in the food & non-food industries, where its list of references is very long and prestigious. Record’s production numbers are impressive too: 7,200 flow pack machines, including M.A.P. (Modified Atmosphere Packaging) and 1,000 automatic feeders and packaging machines are designed, produced and supplied by Record worldwide.

One of the company’s most highly developed solutions is the Jaguar, a horizontal flow wrap machine. “It is a technologically advanced packaging machine equipped with exclusive accessories, designed to be used in

Allen-Bradley CompactLogix programmable automation controller

Allen-Bradley Kinetix 5500 servo drives

One of Record’s most highly developed solutions is the Jaguar, a horizontal flow wrap machine

automatic high-production lines and is characterized by its high performance and high speed,” Mr Galimberti explains. “It has been designed to pack cereal bars or snacks and can run at up to 700 packs per minute.” The Jaguar is suitable for different kinds of products: bakery, biscuits, confectionery, etc.

The machine receives the products from the food processing line, is fed by flexible film reels and runs on continuous cycles. Naked products are fed into the machine in a single lane and are flow packed at a very high speed. Rotating jaws – the Jaguar™ Rotating Seal – using hot or cold sealing materials, provide sealing. The packaged products are then moved to the secondary packaging machine, where they are inserted in cases or boxes.

One of Jaguar best features is its ability to keep product quality constant over time; that is why Record selected the best components to equip it. “Our reputation on the market is due to the high technology, the quality and the efficiency our machines offer to our customers,” Mr Galimberti points out. “We develop our solutions relying on integrated automation, energy saving programs and sustainable materials. We know this approach leads to more expensive machines, but we also know from our experience that customers are willing to pay for these values.” Record selected the Allen-Bradley® CompactLogix™ programmable automation controller (PAC) from Rockwell Automation to control the automation system of its machine.

“In this specific case, the machine had to be delivered to a Mexican customer, who was already familiar with Rockwell Automation products and wanted the machine to be equipped with them,” Mr Galimberti explains. “In fact, Rockwell Automation is the best-known brand in America; American end users have a deep knowledge of its hardware and software solutions and find that Rockwell Automation’s customer and technical service best fit their needs.”

The electric cabinet of the Jaguar includes two CompactLogix PACs, Allen-Bradley Kinetix® 5500 servo-drives and single-cable VPL motors with a single connector system. Allen-Bradley PanelView™ Plus 700 graphic panels have been selected for the visualization system. The

CompactLogix PAC controls the synchronization between the conveyor and the film, arranging the products entering the machine at random, the film unwinding and the longitudinal and transversal sealing operations. All the devices are connected via EtherNet/IP.

The tight integration between the programming software and the motion and control devices in the CompactLogix PAC fit this application perfectly, reducing the development time and cost. As Mr Galimberti states: “Programming efforts were reduced thanks to Studio 5000® Logix Designer, the intuitive and user friendly software environment provided by Rockwell Automation.”

Furthermore, there were some technical benefits that Record experienced too: minimized wiring and an increased flexibility for future changes and customisations on the machine.

Eased maintenance and troubleshooting, minimized installation time and reduced training time are other advantages the end user can obtain thanks to the Rockwell Automation solutions implemented on the machine.

“Efficiency and performance are closely connected to the correct use of the machine and the fact that our customer is aware of Rockwell Automation solutions helps them to better manage the machine,” Mr Galimberti concludes. “We can say that Rockwell Automation products allow us to help our customers in improving their Overall Equipment Effectiveness rates.”

For more information, contact: Record SpA Ivo Galimberti, Sales & Marketing Manager Phone: +39 031 850607 Fax: +39 031 850704 E-mail: [email protected] www.record.it

Allen-Bradley, CompactLogix, Kinetix, LISTEN. THINK. SOLVE., PanelView Plus, Rockwell Automation and Studio 5000 are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVATrademarks not belonging to Rockwell Automation are property of their respective companies.


Solutions in Action

A pioneer and expert in SLEEVER® technology (heat shrink sleeves) for 35 years, the Sleever Machines® Group, which is based in Morangis (in the greater Paris area, France), boasts a team of over 70 specialist technicians and engineers.

Engineering is its main fi eld of interest: The Sleever Machines Group was jointly responsible for developing and producing a complete range of equipment designed for sleeve conversion: single and double-head positioning machines, steam, infrared and hot air shrink applicators, special machines.

The Sleever Machines® Group works with the latest CAC tools, development (computerisation, control systems, motion control), project management and after-sales services to develop machines which meet the needs of the food (liquids and solids), perfume, cosmetics, pharmacy and care products industries, etc.

Recognised the world over for their immense reliability and fl exibility, Sleever Machines Group uses fundamental components that are the backbone of SLEEVER® technology:

• Positioning kinematics (vertical or horizontal),

• Continuous sleeve transfer,

• Rotary cutting,

• Servomotors and total synchronisation of motion,

• Rapid format changeovers and preventive maintenance, etc.

Allen-Bradley CompactLogixprogrammable automation controller (PAC)

Allen-Bradley PowerFlex 525 variable-speed drive

The new range of SleeverCombi machines from Sleever Machines Group is designed for positioning and shrinking sleeves. It uses two technologies for shrinking: infrared and steam. This equipment is designed to manage all types of shape, using all types of film (PET, OPS, TPE, etc.).

Within this range, the SleeverCombisteam® is a technological first, combining operational savings with a reduced footprint. This new concept is a real technological breakthrough and a true innovation in the world of heat shrink sleeves.

The SleeverCombisteam® machine is monoblock, compact and incredibly flexible. It boasts excellent ergonomics, with the control functions for positioning and shrinking accessible on a single touchscreen console:

• Shrink tunnel raising/lowering function.

• Safety device management.

• Storing and editing of setting parameters.

The SleeverCombisteam® is completely transparent, a new benefit which means the product can be monitored from entry, during the sleeve positioning and shrinking stages, until its discharge.

The machine can be equipped with options specially for the markets it is aimed at: control module (presence and position of the sleeve, sleeve connection), micro-perforation, marking, vision/ orientation, etc.

Sleever Machines Group’s aim is to meet the daily needs of its customers by offering a new sleeve distribution module with automatic connection, and tool-less format changeovers in under 15 minutes.

The SleeverCombisteam® enables the recycling of PET bottles for the beverage market to be increased and the carbon footprint of plastic packaging for the dairy product market to be reduced.

Thanks to the incredibly fine new Sleever films (just 20 microns thick) and the optimum production speeds (1000 bpm), the SleeverCombisteam® allows users to manage their use of consumables, thereby reducing their manufacturing costs.

The control system for the SleeverCombisteam® is based on Rockwell Automation motion and automation solutions: the Allen-Bradley products used include an Allen-Bradley® CompactLogix™ L36 PAC, an Allen-Bradley PowerFlex® 525 adjustable speed drive, an Allen-Bradley Kinetix® 350 servo drive, an Allen-Bradley PanelView™ 6 Plus display terminal and TLY-A and VPL series servomotors.

The use of these products has enabled the Sleever Machines Group to record a significant drop in the amount of cabling used and to give the SleeverCombisteam® even greater flexibility in terms of future adaptations. The solution adopted also allows the Sleever Machines Group to offer remote maintenance for its customers’ machines and to reduce their installation and start-up time.

For the Sleever Machines Group, supplying a piece of equipment is just the beginning. A purchase is accompanied by a complete range of services, covering everything from installation and set-up

on-site to after-sales, and including training, line monitoring audits, spare parts and remote maintenance. In this context, Rockwell Automation’s international coverage, in both commercial and technical terms, the services offered across the world and the growing demand from Sleever’s key customer accounts were determining factors in choosing Rockwell Automation.

The SleeverCombisteam® is already being used on production sites for the major agri-food, cosmetics and pharmaceuticals groups, such as Abott, Danone, Johnson & Johnson, Bacardi, etc.

For more information, contact: Jérôme DUEZ European Sales Director Sleever Machines Group Phone: +33 (0)1 69 74 75 76 E-Mail: [email protected] www.sleever.com

Listen. Think. Solve., Allen-Bradley, CompactLogix, PowerFlex, Kinetix and PanelView are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication OEM-AP344A-EN-P – April 2014 Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.

Solutions in Action

With a 7,500 m2 facility in Istanbul, Turkey, Somtas produces paper bag making machines, sheet-fed laminating machines, slitter-rewinder machines and flexographic printing machines – all under ISO 9001-2000 quality certificates.

The company is active internationally and its products can be found all around Europe, the Middle East, North Africa and, of course, in Turkey. Its production and services are accredited by CE certificates, which shows how much it cares about its customers both before and after sales.

The company’s mission is to develop progressive solutions for the packaging industry while stimulating its employee and sub-contractors to create innovative ideas in terms of efficient production and quality control. It takes suggestions from its customers and then develops them into successful products, while keeping one eye on social responsibility and the environment.

Two of the company’s machines ranges, the Bag Master and Slitter families make use of contemporary automation technology and deliver the flexibility demanded by customers.

The Bag Master range represents leading technology in the paper bag making industry equipped with in line flexographic printing. Furthermore, the machine is designed for making windowed bags, with film windows. All main setting are adjusted electronically from the control panel within a couple of minutes. The highest performance makes it possible to run the machine from 150 to 250 m/min, depending on the model.

Allen-Bradley PowerFlex 4M variable speed drive

Allen-Bradley CompactLogix L36 programmable automation controller

The Slitter range offers solutions for BOPP-CPP-PVC-PE and Triplex-Doublex A quality paper and stickers slitting. The company is mainly oriented towards providing Slitter Rewinders for Paper Converters.

Both machine ranges use a variety of Allen-Bradley® products from Rockwell Automation depending on the machine size and the application. These include: Allen-Bradley Kinetix® 3, 300, 5500 and 6500 servo drives; Allen-Bradley PowerFlex® 4M, 40, 753, and 755 variable speed drives; Allen-Bradley CompactLogix™ L30 , L33, L36 and L16 programmable automation controllers for motion control; Allen-Bradley MicroLogix™ 1400 PLCs; and Allen-Bradley PanelView™ plus 1000 for the operator interface.

“Our machines offer very good performance and durability and our difference is that we can offer high speeds coupled to a good price,” explains Mehmet Ebiller, General Manager at Somtas. “We opted for an automation infrastructure from Rockwell Automation because of the technical support we receive and the service back up. Rockwell Automation is a very big company and this gives us a lot of confidence.

“We benefit from a shorter more streamlined design process and reduced programming efforts,” he continues. “We also find troubleshooting easier and we have greater flexibility for future changes. Our customer, on the other hand, see reduced energy consumption and improved personnel and machine safety. We are able to save them precious time and money.”

For more information, contact: Somtaş Krom ve Mak. San. Tic. Ltd. Şti. Phone: + 90 212 886 3222 E-mail: [email protected] www.somtas.com

Listen. Think. Solve., Allen-Bradley, Kinetix, PowerFlex, CompactLogix, MicroLogix and PanelView are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication OEM-AP308A-EN-P – MARCH 2014 Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.

Solutions in Action

Created in 1990, TECMA pack designs and sells a wide range of machines and equipment for secondary and tertiary packaging, from its Rebais and Coulommiers sites in France. Its range extends from box mechanisation to comprehensive end-of-line solutions. Mechanical assembly, wiring, automation... TECMA pack covers all the manufacturing phases of its equipment, from design to development, which provides a guarantee of quality.

In April 2014, TECMA pack purchased the company ARIES PACKAGING.

From box forming presses to palletisers, also covering connection conveyors, divergers, convergers, case packers, lid fitters, stacker-lifters and more, TECMA pack offers flexible, ergonomic and long-lasting solutions, combining mechanical reliability and premium-level automation.

Specialising in comprehensive end-of-line systems for thermo-formed & pre-formed jars and bottles, TECMA pack develops standard and tailor-made machines mainly for the dairy industry and, by extension, for all potential applications of thermo-formed & pre-formed jars and bottles.

Allen-Bradley CompactLogix

The new FM 6000

Allen-Bradley Kinetix 5500

With more than 2200 machines to its name, TECMA pack has within the space of a few years become an essential player in terms of the design and manufacture of packaging machines and engineering of comprehensive end-of-line systems. The company operates worldwide, both with SMEs and with big food processing customers. The solutions offered by TECMA pack are characterised by a balance between efficiency, simplicity and cost optimisation, as well as a completely customer-focused business philosophy.

This combination of skills gives TECMA pack control of the whole process, enabling it to offer the solutions best suited to the needs of each customer, with the requisite degree of personalisation.

The new FM 6000 box forming press, presented at the Emballage 2014 show, rounds off the TECMA pack range of box mechanisation machines. This forming press, which combines performance and ergonomics, is capable of achieving a high output of boxes tailored to the requirements of UV reduction. Based on mechanical simplicity and reliability, the FM 6000 is actually capable of producing up to 6000 trays per hour. It meets the expectations of customers, who have to deal with UVC reductions alongside limitations in terms of investment and physical dimensions in existing plant floors. With a

production capacity equivalent to that of two current machines, the FM 6000 provides a substantial space saving in line layout: as well as savings in terms of maintenance and servicing which are just as advantageous.

In order to guarantee optimum performance, for the on-board equipment in its machine TECMA pack has chosen standards recognised worldwide. The FM 6000 is controlled by a Rockwell Automation system comprising an Allen-Bradley Logix – CompactLogix family programmable automation controller, a PanelView Plus human-machine interface, three Kinetix 5500 axis systems and VPL servomotors, all communicating via EtherNet/IP.

Thanks to this solution, TECMA pack has been able to reduce the wiring required and the costs, achieve the necessary flexibility to adapt to future developments and – most of all – offer its customers a machine with unrivalled performance.

For more information, contact: TECMA pack Pierre Therville Phone: +33 (0)1 64 04 51 80 E-mail: [email protected] www.tecma-pack.fr

Allen-Bradley, CompactLogix, Kinetix, LISTEN. THINK. SOLVE., PanelView Plus and Rockwell Automation are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVATrademarks not belonging to Rockwell Automation are property of their respective companies.

Publication OEM-AP406A-FR-P – October 2014 Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.

Solutions in Action

“Tosa Group is an Italian company operating only at levels of excellence, acting in 115 countries. For almost 40 years we have been the end-of-line reference partner for pallet handling systems, stretch film wrapping, heat-shrink film bundling and strapping systems. We are faithful to the mission which has been guiding us since the beginning: constant search for innovation and absolute quality are necessary conditions for the Tosa Group,” Fabio Tosa, Ceo of Tosa Group, says.

Today the Northern-Italian machine manufacturer headquartered in Santo Stefano Belbo, near Cuneo, serves both large, medium and small companies acting worldwide in the food & beverage, homecare and chemical industries. About 90 percent of Tosa’s machinery is sold overseas.

One of the most recent example of Tosa Group’s excellence in technology is the new Tosa 126, a fully automatic pallet stretch wrapping machine with rotating film-roll. The machine is designed to be integrated into an end-of-line plant. During the exhibition the wrapper is integrated in a line which includes also an automatic strapping machine CAM 34 for horizontal strapping operations and a pallet handling system completely produced by Tosa.

The machine, with a painted steel frame, features the Tosa low maintenance technology: up and down movement of the rotating ring by toothed belts are completely maintenance and lubrication free, so as the machine lifting system with gearless direct motorization.

Allen-Bradley controlLogix programmable automation controller

Allen-Bradley PowerFlex 525 inverter

The Tosa 126 includes different units. The first one is an electronically controlled pre-stretch carriage system - version Tosa 492 suitable to prestretch the film up to 400%. The second one is an automatic cutting, hooking and sealing unit suitable to seal the film at the end of the wrapping cycle on the counter-bar. The third unit is the Tosa 892 film roping system which allows to set the band reduction value in any position on the pallet with accurate precision.

The Tosa 126 features also a pantograph top presser to fix the products on the pallet during wrapping operations, which brings maximum flexibility of use, reduction of overall height of the equipment and optimization of energy consumption.

Last but not least, the wrapper integrates a system for the automatic application of vertical corner posts for the protection of the edges of palletized loads and an automatic stretch film-roll change system. USA- and EU-patented, this device allows to replace automatically exhausted film-rolls in 30 seconds without stopping the wrapper and without operator intervention.

The new Tosa 126 wrapper, which is fully equipped with a Rockwell Automation control solution, has the ability to work at a maximum speed of 140 pallets/hour, featuring a maximum film-roll rotating speed of 55 Rpm. Both film pre-stretch system and film roping system are driven by brushless motors allowing to perform customized wrapping programs with the maximum precision, to optimize film distribution and to increase pallet stability, yet minimizing overall maintenance, film consumption, giving significant cost saving.

The main functionalities of the wrapper are managed by an Allen-Bradley® ControlLogix® L72 PAC (programmable automation controller) supplied by Rockwell Automation. The up and down movements of the rotating ring are controlled by Allen-Bradley PowerFlex® 525 inverters, in order to obtain the maximum positioning precision. The Allen-Bradley PowerFlex 525 inverters manages also the rotating movement of the ring, as to perform an excellent and precise control of the overall rotating operations. Additional components of the machine include a photocell automatically detecting the different pallet heights and Allen-Bradley smart safety relays.

The Rockwell Automation platform for the Tosa 126 is completed by an Allen-Bradley PanelView™ 1000 (10’’) HMI, which allows operators to visualize each manual operation or any possible machine failure. Through PanelView 1000 HMI, operators are also able to program different wrapping recipes according to each format, or even to visualize and control products featuring variable parameters of film tension and wrapping path. Furthermore, from PanelView panel, operators can set up pre-stretching interchangeable ratios from 0 to 400 percent and wrapping cycles with variable pre-stretching configuration.

“We selected a Rockwell Automation platform because we recognized in the automation supplier a strong technological excellence and an extremely valid worldwide service support, which are both strongly appreciated by our customers,” Fabio Tosa explains. “The Rockwell Automation team helps our technical department’s people to improve their expertise and their technical knowledge on Allen-Bradley solutions. Furthermore, we are able to minimize machine installation time and overall machine costs, while enhancing the machine’s flexibility for future change.” In addition, Rockwell Automation supported Tosa’s engineering team to get the most out of the Tosa 126 concept of ‘smart wrapping technology’. “The Tosa 126 wrapper integrates our smart wrapping technology, which allows to optimize film application during wrapping cycles and to control precisely film tension at the load palletized corners,” Fabio Tosa says. “Each operation can be fully monitored through the HMI panel, as well as it is possible to store historical data about film consumption, cycle timing, wrapping numbers, product format, wrapping recipes, film typology for each palletized load.”

For more information, contact: TOSA SpA Phone: +39 0141 841000 Fax: +39 0141 841099 E-mail: [email protected] www.tosagroup.net

Listen. Think. Solve., Allen-Bradley, ControlLogix, PowerFlex and PanelView are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication OEM-AP336A-EN-P – MARCH 2014 Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.

Solutions in Action

Handle applications, pick and place, palletizers and multi-pack machines, with shrink-wrap or adhesive tape clustering solutions, are the core business of Twinpack, an Italian company which was founded 20 years ago and was suddenly successful, thanks to the revolutionary idea of making more comfortable pack handles by joining a cardboard strip to the adhesive tape.

Twinpack is now a well-known player in the packaging industry and has prestigious customers among the leading international companies in food & beverage, chemical and pharmaceutical industries. “We are an export oriented company”, Lucia Gazzola, Sales, says. “Our machines are installed in France, Germany, Spain, Northern Europe, Russia, North Africa and China”.

At Twinpack, integration is the key word. “The integration of every stage of the production process is a must for us, because we think it is the right way to increase efficiency”, Lucia Gazzola points out. Constant investments in technology are another cornerstone in Twinpack vision, as they allow the company to constantly provide innovative solutions, which include brushless motors, carbon-fiber arms and centralized control software.

Allen-Bradley CompactLogix™ L36 PAC

Allen-Bradley Kinetix® 6500 servo-drives

One of the most innovative solutions provided by Twinpack is the electronic double track machine for the placing of self-adhesive handles on packs of bottles of water.

The packs arrive through the in-feed conveyor and are automatically slowed down and spaced via a series of Intralox conveyors.

An electronically controlled motor-driven roller unwinds the adhesive tape, while a mechanical double cam system manages the placing of the cardboard (or other materials) on the adhesive. An electronic mono-applicator head puts then the handles on the packs of bottles, which continuously transit through the machine. The operation is fully controlled by electrical-axis servomotors. The alignment of handle and cardboard is electronically controlled too.

“Flexibility, reliability and high-end technology are the features that make our machine unique on the market”, Lucia Gazzola states. “Furthermore, it combines good performances - its maximum output rate is 120 packs per minute for each track - and ease of use, as it is fully synchronized and automated”.

The combination Gazzola refers to could be obtained by using a trusted automation and control technology. “The final destination of our machines usually is the facility of a multinational company, who has plants worldwide and wants to be sure that spare parts and technical support can be always available”, she says. “Rockwell Automation products are very appreciated by these companies, as Rockwell Automation is a worldwide automation supplier too and its technology is well known for its excellent reliability”. As a consequence of this, Twinpack engineers have become very familiar with Rockwell Automation hardware and software solutions: “These products are expected to make our job easier and easier”, Carlo Ceruti, Production Manager, adds.

The control core of the machine was then built using the Rockwell Automation CompactLogix™ platform, which integrate control, motion and drive functionalities. “We selected a CompactLogix L36 PAC and Kinetix® 6500 servodrives”, Ceruti says. “The CompactLogix platform manages the mono-applicator head motion and the axis synchronization”. The devices on the machine are connected

through Ethernet IP and are configured using RS Logix 5000, the common programming environment provided by the CompactLogix platform.

“Rockwell Automation products were carefully selected accordingly to our specific needs and proved to be the right choice in combination with the different devices implemented on the machine”, Ceruti comments.

As far as it concerns the real benefits Twinpack has received by using the CompactLogix platform, Ceruti says: “We noticed that Rockwell Automation technology helps to reduce startup time and to troubleshoot operation problems”. Besides, increased flexibility for future changes, reduced energy consumption, quicker changeover time and eased maintenance are interesting advantages both for Twinpack and the end-user.

“In short, Rockwell Automation technology allows us to deliver an easier to use machine to our customer without compromising on quality and reliability”, Ceruti concludes.

For more information, contact: Twinpack srl Phone: +39 0523 554020 Fax: +39 0523 554728 E-mail: [email protected] www.twinpack.com

Allen-Bradley, CompactLogix, Kinetix, LISTEN. THINK. SOLVE., CompactLogix, Kinetix, RSLogix, Rockwell Automation are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVATrademarks not belonging to Rockwell Automation are property of their respective companies.


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