Playbook Primary Pkg Mc 2013

8/13/2019 Playbook Primary Pkg Mc 2013

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packagers playbook serieseducation for packaging professionals

PRIMARYPACKAGING LINEEQUIPMENTPLAYBOOK

HOW TO SUCCESSFULLY IMPLEMENTPRIMARY PACKAGING LINE EQUIPMENT

8 Coding trends for primary packaging8 Coding survey results8 PackML and when to use it8 How to compare machines at a trade show

2013Edition


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packagers playbook serieseducation for packaging professionals

Sponsored by2 / 127

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PRIMARY PACKAGING LINE EQUIPMENT PLAYBOOK

Contents 3 / 127

5 All the packaging experts who contributed to this Playbook

7 Your Playbook for building a better packaging line

10 Five trends in liquid lling equipment

13 Seven tips for buying liquid lling equipment

17 Best practices when implementing weigh/lling equipment

20 Key implications of FSMA for food packaging suppliers

26 Auger lling equipment trends and buying tips

30 Nine best practices for selecting capping equipment

33 In-line cappers versus rotary chuck-style cappers

35 Trends in coding/marking for primary packaging

37 Ten tips for buying coding/marking systems for primary packaging

42 Comparing coding technologies

48 Best practices for specifying conveying and container handling equipment

Contributors

Introduction

Equipment Strategies


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Contents 4 / 127

89 Ten nancial justications for new equipment

92 Best practices for specifying packaging machinery

98 Vendor evaluation methodology for packaging equipment100 Tips on nding the right equipment supplier

105 Seven tips for comparing machines at a trade show

108 Roadmap for a successful Factory Acceptance Test

114 Eleven tips for a successful packaging line start-u p

119 Benets of PackML and when to use it on your line

122 How projects fail: 11 pitfalls to avoid

Project Strategies

Equipment Strategies continued

53 Best practices for buffering and packaging line design

57 How to calculate Overall Equipment Effectiveness: A practical guide

71 Trends and drivers for machine vision technology

77 Best practices in specifying vision systems

80 Metal detection, X-ray, and checkweigh trends

82 Best practices in specifying inspection systems

86 Trends and tips for specifying induction sealing equipment


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Contributors 5 / 127

Sunny IshikawaEngineering Research FellowWrigley

Glenn WhitesidePackaging Engineer, CPPSynthes (USA)

Dave HoenigPrincipalDH Technical Consulting, LLC

Paul H. DavisProject EngineerRyt-way Industries, LLC

Roy Greengrass P.E.Senior Engineering ManagerDel Monte Foods

Paul ZepfP.Eng., M.Eng., CPPZarpac Inc.

Stan Walulek Vice PresidentMichels Bakery, Inc.

Greg FlickingerVP Manufacturing and Corporate Engineering,

Snyders-Lance, Inc.

Shawn FrenchEngineering ManagerSun Products

Matthew CourtesisPackaging Dept. SupervisorBoston Beer

Adam Pawlick Director of PackagingBay Valley Foods

Paul RedwoodSenior Research Engineer

Church & Dwight

The following brand owners, consultants, and engineering experts contributed to this Playbook:
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Contributors 6 / 127

Sterling AnthonyConsultant

Tommy LancasterChief Operating OfficerBryson Industries

Curtis Wardaugh, P.E.PresidentMedalist Engineering, P.C.

Several other brand owners wereinterviewed for this Playbook onthe condition of anonymity.

Additional Contributors: We gratefully acknowledge the expertiseof these supplier contributors:

Accutek, All-Fill, Apacks, Axon, Cognex, Cozzoli Machine Co./MRM/Elgin,Delkor Systems, Domino, Douglas Machine, Econocorp, Fanuc Robotics,Fowler Products, Griffin-Rutgers, Heat & Control, ID Technologies, Lion Precision,MGS Machine, Morrison Container Handling Solutions, Nalbach Engineering,Optima-USA, Pearson Packaging Systems, Spee Dee Packaging Machinery, Thermo Scientic, Videojet, Weighpack, Yamato, Z.I.T.O. (Zito Induction Technology Options)

Elizabeth Barr FawellAssociate, Food and Agriculture GroupHogan Lovells US LLP


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Introduction

FORWARD PLAYBOOK RETURN TO CONTENTSADD COMMENT

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Your Playbook for buildinga better packaging lineSpecifying and installing a modern, automated packaging line is essentially an exercise inteam building. You may be in your present position because of your technical knowledge andexperience, but packaging line experts have told us over and over that good communicationskillswithin your plant and outside of itmay be just as important to the success of your

new or upgraded packaging line. You must know your product and your lineand be able tocommunicate that knowledge to both internal and external members of the team. Learn whatpackage machine builders need to know in order to give you the solutions you want.

The idea behind our Playbooks is the creation of one source that spells out all the tricks andtips associated with buying, testing, commissioning, and starting up packaging equipment. To unlock these secrets, we spoke with or consulted with dozens of sources. Most of theseconsisted of in-depth phone interviews with experts in the eldengineers and managers atleading consumer packaged goods companies.

We also talked to suppliers, which gamely set aside their sales hat and spoke honestly aboutbest practices and pitfalls to avoid. Remember that while you may buy one ller or inspectionsystem or coding/marking system in a given yearif that manythe companies selling thatequipment have been through dozens of projects in that same time period. Learn from theirexperiences.
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Introduction


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In short, what youre reading is the collective thinking of an industry, representing hundredsof years of packaging experience, distilled into a short, actionable, bulleted style that makesfor easy reading.

This particular Playbook, like our other successful Playbooks in the areas of exible packaging,labeling, and package development, has been updated for 2013. The Primary Playbook coversthe front half of the packaging linefrom unscrambling through induction sealing. Newmaterial in the areas of weighing/lling, robotics, and primary coding has been added tobring these subjects up to date.

You will also want to download the End-of-Line Equipment Playbook, which coverseverything on the back half of the packaging line, from cartoning, case packing, and shrinkbundling through palletizing and stretch wrapping. The two Playbooks will equip you well foryour next project. (See all our Playbooks a t Packworld.com/playbook .) All of our Playbooks aredesigned to be read either on the screen, or printed out.

A nal word. The entire cost of producing and distributing this Playbook has been

underwritten by the companies that have sponsored it. We thank them for their support, andwe thank you for reading.

continued

Your Playbook forbuilding a betterpackaging line
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Introduction


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Our Editor:

Melissa Larson has been writing about the packaging and converting industries since 1984.She was senior editor of Packaging magazine, was the founding editor of Pharmaceutical andMedical Packaging News , and was managing editor of Converting . She has also blogged forPMMIs Connected Communities and other packaging industry clients. She resides in Barrington, IL.

Melissa LarsonContributing Editor


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Five trends in liquidlling equipmentSpeed and precision are the hallmarks of liquid lling systems. As the economy improves,packagers are under the gun, using all their planning skills to take care of business whileutilizing the equipment already on the oor, and perhaps contemplating new technology.Heres what they are discovering is available in liquid lling:

1. Shorter lead times: Short build times are the norm as the economy recovers, as mostpackagers are dealing with multiple product lines, projects, and deadlines. They are searchingfor suppliers that can deliver a full packaging line with the shortest build time. Budget is still aconcern, but the growing demands, in particular, of the food and beverage business dictate afully integrated solution on a tight deadline.

2. Flexibility and adaptability: Packagers continue to look for exibility in machineryso they can package products with a wide range of containers, caps, labels, sleeves, andproducts. They want machines that can handle different size/shape containers as a standardfeature, without additional add-ons or a custom solution.

3.Quick changeovers: SKU proliferation and retailers that order at the last minute toavoid holding stock have driven the need for faster changeovers in recent years. This has ledto the development of technologies for quicker cleaning, eliminating pistons, cylinders, and

valves that have to be removed, cleaned, and reinstalled. Instead, such components can be

Source: Apacks


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FORWARD COMMENT RETURN TO CONTENTS


Equipment Strategies 11 / 127

continued

Five trends in liquidlling equipment

cleaned with hot water or steam straight through the llingnozzle. On in-line machines, theres also a trend favoringuniversal change parts, reducing or in some cases eveneliminating the need to remove parts for a size change.

4. Compliance with the Food SafetyModernization Act (FSMA): Cleanability per FSMAis a big concern for ller machine builders. Fillers havea tendency to have complex uid pathways due to themany pistons, pumps, and check valves inherent in theirdesign. Cleanability goals are quick disassembly with notools needed, disassembly of hoses, etc., and no hidden

uid pathways.

5. Multiple-function machines: Packagers areasking for machines that can perform multiple functionsbeyond that of the traditional monobloc ller/capper. Oneexample cited was a machine that orients bottles and capsto one another as well as to the nal case-packing system.CPGs also want more equipment exibility to accommodate
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continued

Five trends in liquidlling equipment

a continually expanding range of packaging formats,including a wider variety of container shapes, sizes, materialstructures, and closure mechanisms. Five years from now,some machine builders predict more complexly integratedmachines with software adaptations that can handle maybefour to six operations (for example, lling, capping, labeling,coding, cartoning, and casing) in one system. Also predictedare multiple production cellsif one module fails, you cantake it out and replace it without having to replace theentire system.
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Seven tips for buyingliquid lling equipment There are several things to keep in mind when selecting liquid llers to ensure the right t foryour application:

1. Understand how the machine affects the product. You need to think aboutthe impact of the ller on the product youre packaging. The state or viscosity of the liquid canbe inadvertently changed, based solely on the construction of the equipment. For example,running a liquid through extra elbows, pipes, and pumps can change the viscosity, resultingin a liquid that is much too thin. High speeds can also impact some products negatively. Youneed to keep the product characteristics front-of-mind when selecting equipment.

2. Understand how the product dictates the type of ller. The type ofmachine utilized for a project is often dependent on beverage/product characteristics and thetype and shape of the containers. Free-owing liquids like beverages work well with a timed-ow or overow machine, whereas a more viscous product might be better suited for a pistonor positive displacement (PD) ller. The ll size or type of container might also determine thetype of machine used. Timed-ow and overow machines are both good for free-owingliquids but differ in how they deliver product to a container. Timed-ow llers are a volumetricll machine, meaning each ll cycle they deliver exactly the same volume of product. These

Source: Apacks


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continued

Seven tips for buying liquidlling equipment

machines are designed for very precise lls regardless of thecontainer shape. However if the container varies in volume,the ll levels may have an inconsistent look. Glass bottlesare a good example of containers that often have varyinginner shapes and volumes.

3. Know the lling challenges of handlingbeverages with pulp or fruit pieces. Pulp or fruitpieces, otherwise known as particulates, require specializedpumps and valves based on the size and density of theindividual particulates. Challenges with lling particulatesarise whenever there is a signicant variance in the size of

the pieces. Pickles are a good example of a product thathas particulates with a large size variance. Small or softparticulates are usually easier to accommodate.

4. Look at ease of cleaning. Pay attention to thecleanability of equipment. As with any product destinedfor consumption, the machine must be made of FDA-approved sanitary materials. Most customers, including

beverage providers, want equipment that is easy to clean
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continued

Seven tips for buying liquidlling equipment

and maintain. When lling bottles, keeping the nozzle cleanis of primary importance to good manufacturing practices.Simpler design is better: Make sure the equipment doesnthave nooks and crannies that can harbor microorganisms.Also look for lling machines that have clean-in-placesystems as a standard feature.

5. Lighten up. Plastic bottle lightweighting continuesto be a major trend, and with cost and sustainabilityadvantages, this trend isnt going away anytime soon. So besure to look for unscrambling and lling technologies thatwill accommodate progressively thinner bottles. Feather

bottles, down to just seven grams of plastic for a half-literbottle, with a short-skir ted cap, call for kinder, gentlerunscrambling and lling.

6. Dont give away product. Dont accept a vendorgiving you a general average in weight variation. You needto know what that percentage is at the actual containersizes you intend to run today and in the future. Giveaway

can actually vary slightly at different container sizes.
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7. Avoid complexity. Complex llers equal complex maintenance needs. The simplerthe machine, the less maintenance, the less training, and the fewer parts that need to bekept on hand. Watch for parts or components that may have the potential to break off. If youdont have a screen prior to the ll head or nozzle, pieces of metal or plastic can get into yourproduct. Even good inspection systems may not be 100% effective in detecting a piece ofmetal or plastic in a metal can.

8. Ask about changeover times. If you know youre lling different products, orthat you may be someday, you need to know about changeover times. Changeover time

reductions are a key factor in boosting efficiency. The goal is quick, repeatable changeovers,so you can get your line up and running again as soon as possible.

9. Know what you need today, but have exibility for tomorrow. Whenselecting a machine, keep an eye on future output. See into Year Two, and think about futurenew products and their lling needs. Look vertically across your products, as well as upstreamin the supply chain. What happens if a key ingredient in the formula of your product changes?Does this mean your nozzles may become ineffective? Think about future lling challenges.

continued

Seven tips forbuying liquid llingequipment


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Best practices when implementingweigh/lling equipmentWeighing can be the most important operation in food processing, and the one with thehighest ROI within your plant. While almost any lling machine can potentially be set up to llby weight, weigh lling is more often used with dry products, such as powders or granules. The challenge is determining the best solution for not only weighing, but also for handling

your product properly to minimize any degradation after the weigher. Condence in boththe equipment and the supplier is vital when you consider the typical life of a weigher can bemore than 25 years. Here are some best practices:

1. Determine the overall system goals, looking at each transfer point. Carefully specifying each component of a system (like a weigher) is important, but allcomponents must work in concert to achieve the desired output, which is accurately lledpackages and efficiently running equipment.

2. Review your products ow characteristics with prospectivesuppliers. Send product samples for machine builders to test and ideally videotape. Thisis time-consuming and somewhat tricky if your product tends to change with transport andhandling, like produce. The trickier the product, the more important the validation.

Source: Weighpack


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3. Carefully examine and document your facilitys environmentalconditions. This includes humidity and temperature of the lling area, as well as bulkstorage. Depending on what is being lled, these conditions may have a damaging effect onthe product. They can even change the consistency of the product enough to have an adverseeffect on the equipments lling ability.

4. Make sure your sanitation practices and maintenance are top-notch.Avoid product buildup on tooling and control services. Choose equipment that is easy todisassemble and clean on a daily basis or as required. Follow a rigorous maintenance schedule

to ensure top production output.

5. Consider how weighing/lling is affected by fresh, frozen, dry, fragileproduct. Weighing is affected by all product conditions, both physical and environmental. The same product will convey, transfer, fall, and handle in a completely different mannerwhen fresh as compared to when it is frozen. The supplier should also have a large selectionof application-specic weighers to choose from, such as:

Gentle-slope weighers for fragile products.

USDA Dairy-approved systems if applicable.

Weighers for fresh, sticky, and large-piece products, such as poultry.

continued

Best practices whenimplementing weigh/ lling equipment


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continued

Best practices when implementingweigh/lling equipment

Weighers designed for RTE (ready to eat) freshproducts, such as salad kits, etc., which are extremelypopular right now but are challenging because theymay change in shipment, and are hard to validate.

6. Consider the unique challenges ofgranulars and particulates. Your supplier shouldhave a range of weigher models to handle different targetweights of granular and powder products. Considerspecifying sift-proof hoppers for your weigher, as well as adust collector for products that create high concentrationsof airborne particulates. You might also want some sort

of secondary automatic bulk loading of product to theequipment so that the machine is never under- or over-lled with product.
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Key implications of FSMA forfood packaging suppliersOn Jan. 4, 2011, President Barack Obama signed into law historic food safety legislation theFDA Food Safety Modernization Act (FSMA). The law has two major themes: prevention andaccountability. Prevention means that food companies need to have controls in place duringmanufacturing to assure the safety of their products and to prevent problems (not just react to

them after-the-fact). Accountability means that food companies are accountable to the Foodand Drug Administration (FDA) to help ensure that their suppliers are making safe ingredients.

Although the law primarily has signicant implications for food manufacturers, importers, andthe fresh produce industry, it also affects the food packaging industry. Importantly, not allprovisions in FSMA apply to food packaging in the same way. Some provisions of the new lawmake food packaging manufacturers accountable to FDA, while other provisions make foodpackaging manufacturers accountable to their customers. In order to help keep everythingstraight, I encourage you to think about a few key principles as you read on.

First, who does the legal requirement apply to? Some requirements apply to foodas dened in the Federal Food, Drug, and Cosmetic Act (FFDCA), and others apply toregistered food facilities.

Second, where is your business in the supply chain? Are you acting as a seller or as animporter/buyer?

Third, who cares about your activities? Is it FDA or your customers (or both)?

BY ELIZABETH BARR FAWELL


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There are two major provisions in FSMA that are particularly relevant to food packagingmanufacturers and their relationships with their food-industry customers: Preventive Controlsand the Foreign Supplier Verication Program. Third-party certication is a tool that may helpease compliance for food packaging companies.

Preventive Controls

The Preventive Controls provision is found in Section 103 of FSMA (FFDCA Section 418). Itrequires all registered food facilities to evaluate the hazards that could affect food manufactured,

processed, packed, or held by the facility and to identify and implement preventive controls tosignicantly minimize or prevent the occurrence of such hazards and provide assurances that thefood is not adulterated and does not contain any undeclared allergens.

As stated above, this requirement applies to all food facilities registered as required by Section415 of the FFDCA. By regulation, FDA has exempted food packaging companies from theregistration requirement (it dened food to exclude food contact substances). This meansthat these companies are exempt from the legal requirement to comply with the Preventive

Controls provisionmeaning such companies are not accountable to the FDA. But in practice,they are still accountable to their customers.

Although food packaging manufacturers are exempt from the Preventive Controls provision,in all likelihood their customersfood facilities that use packaging materials to packagefoodsare subject to it. And it is important to understand that one of the preventive controlsthat registered food facilities will need to have in place is a supplier verication program.Because food manufacturers will be required by FSMA (and FDA) to verify that their suppliers

continued

Key implicationsof FSMA for foodpackaging suppliers


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continued

Key implications of FSMA forfood packaging suppliers

If you are an importer, you can use third-party certicationas a verication activity. That is, you can require yoursuppliers to get certied. Then, meeting the FSVPrequirement is much easier. If you are a supplier, you canuse third-party certication to show your customers youhave rigorous programs in place to ensure safety andquality. You can show your customers you are certied,and then they can more easily satisfy their obligationsunder FSMA. (Please keep in mind that you are not legallyrequired by FDA to use third-party certication. I am merelysuggesting it as a potential tool for your consideration.)

ConclusionIn the end, the passage of FSMA means that big changesare coming for food companies everywhere, and thatapplies to makers of food packaging as well. As you thinkabout preparing for compliance with the law, be sure you:
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Auger lling equipment trendsand buying tipsWhat has most affected the design of auger lling equipment in the last year or two? It boilsdown to these trends:

1. Greater throughput and reliability with servos: For more than a decade, servo-motor technology has increasingly found its way into dry lling lines to become a mainstreamtechnology for all package sizesfrom club packs to stick packs, K-Cups, and single-serve packs. This technology allows precise control of acceleration rates and revolutions for greater accuracyand repeatability as well as reduced product giveaway. Along with the accuracy of turning onand off cleanly with every ll, servos also can automatically shut down in the event of a linestoppage, eliminating the burnout of old AC motor and clutch-brake designs. Also in contrastto older AC systems, servos use fewer parts for reduced maintenance. These benets, taken as awhole, have allowed greater management of complex lines and greater condence to expand,for instance, a K-Cup lling line from two to eight or more lanes.

2. Quicker changeover: Along with greater control and reliability of dry lling lines,machine design enhancements open new opportunities for making incremental gains in capacity,especially in the area of changeover. For example, when reconguring the appropriate numberof lling heads for a change in package or product, new designs offer easy access to parts,speeding cleaning and changeover. This can be seen in the reduced tools, and in some cases



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tool-less changeover procedures, that contribute to greater productivity for greater throughput,while at the same time reducing the risks of unnecessary tools and loose parts in the productionenvironment.

3. More powerful controls: The wide adoption of programmable controls has led tomore powerful management and integration of lling equipment. Current-generation dry llingequipment is typically integrated with upstream infeed systems and downstream baggers, suchas horizontal or vertical form/ll/seal systems. Additionally, checkweighers further downstreamcommunicate with that equipment to automatically adjust feed and ll settings and prevent drift

in weight and other parameters. The advent and adoption of control and software standardshave led to more cost-effective, plug-and-play compatibility for great reductions from softwareprogramming to hardware costs that range from wiring and maintenance to spare-parts stores.

4. Increased sanitation: Particularly in the food industry, packagers are looking atsanitation levels more closely than ever before. New laws such as the Food Safety ModernizationAct in the U.S. have prompted the design of machines that are more sanitary and easier to clean,reducing or eliminating cracks or crevices that can capture food particles, and streamlining

extraneous machine parts that might inhibit cleaning. Suppliers are also upgrading from 304stainless steel to 316 stainless steel, for the additional resistance to corrosion and staining thehigher grade delivers.

continued

Auger llingequipment trendsand buying tips



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continued

Auger lling equipment trendsand buying tips

Buying advice

When it comes to purchasing auger lling equipment, its criticalto make the equipment manufacturer aware of your container orpackage design as early in the process as possible. A manufacturermay be able to give input into package design that will positivelyimpact line speed. For example, if your container opening is toonarrow, increasing it by of an inch may greatly increase llingspeeds, as well as provide benets to the consumer regardingease of evacuation of the product.

To select the right equipment for your application, the

ller manufacturer will need to know the target weightand the speed requirements in packages per minute.Accuracy requirements should also be known. These threefactorsweight, speed, and accuracyare not alwayssimultaneously achievable. You might need to give up oneto get the other.

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Auger lling equipment trendsand buying tips

Of course, this means that the product you will put inyour container is just as important as the container itself.Products that are free-owing like salt or sugar are handleddifferently from those that are lumpy or prone to bridging.Density is another factor to measure, and if you dont knowit, the machine manufacturer should have the resources andcapabilities to account for it.

A holistic consideration of package, product, and machinecharacteristics can speed machine design, testing, andsuccessful implementation of your dry lling line.

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Nine best practices forselecting capping equipment There are few key things to keep in mind when buying and specifying capping machinery:

1. Know your closure. The tip we heard the most, from both suppliers and end users,was that you must understand the tolerance of the closure itself and then marry the material

tolerance to the machine tolerance. You must completely understand all the geometry,tolerances, and measurements of your closures before you order a machine. For example:What sort of pressure does a snap-on closure take? With a screw-top closure, you mightbe able to use 20 times more force, but how many times do you have to rotate it? Often,packagers dont take into account the type of closure and balance the application torque andremoval torque required by the consumer. Induction sealers add another variable, as theymay loosen caps, requiring the addition of a retorquer. Additionally, every closure has a decaytime on the removal torque; you need to know the decay time, because it may loosen on theshelf. Know this information and share it with your supplier.

2. Consider both the consumer and the machine. Because the cap hasto interface with both. Consider the size of the bottle opening from both a lling andevacuation standpoint. Also evaluate whether to use a single-closure assembly versus atwo- or three-piece cap assembly. The geometry of the package must be considered rst,and then you should explore the type of feeding system you need to deliver the closures tothe capping machine.



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3. How will the closure design interface with the machine function? Before you consider centrifugal sorting bowls, you must know the height and diameter of thepart versus the length of the part, as well as the weight bias, to determine if it will sort well, orat all. Other considerations include: Do the sidewalls have paper or not? This makes it moreunstable in handling. You must look at this in a very granular fashion; you must know whatthe natural tendency of a part is before you toss it into a sorting bowl. Its critical to knowhow the cap design will interface with the machine function. And you have to know thatbefore you apply any sort of force to it. You have to nd a way to differentiate shapes in thesorting bowl. Once you know the natural tendencies of a part, you can assist those tendencies

through the design of your machinery, and you will achieve more reliable operation whencapping and handling. One philosophy is to permit machine function to drive closuredesignin other words, make sure that the design of the cap is compatible with whatstypically available in the way of unscrambling and orientation equipment.

4. Consider future closure exibility. Like any other packaging machine, try toanticipate future needs. Capping machines may need to be able to deal with a variety ofdifferent types of closures over time. Over the years, cap designs and applications have

become increasingly complex: For example, spray-through caps must be oriented with thegraphics on the container.

5. Rotary capper considerations. When looking at rotary machines, examine thenumber of heads and infeed method (starwheels or screws). A key element to look at is howthe cap is applied. Servo-driven chuck applications permit easy changeover to differentclosure styles. Closure pickup is critical, as is chuck handling. Look at the cappers centeringmechanism and any anti-rotation devices to ensure proper closure placement.

continued

Nine best practicesfor selecting cappingequipment



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6. The need for speed. Think about how many heads are required to achieve yourcurrent line speed, and make sure you have the ability to add heads later for higher-speedapplications.

7. Examine container handling and stabilizing. For some lighter-weight plasticbottles, youll need to look at the machine to assess how well it holds the container tightly inplace during the capping application and torquing to assure a good seal, especially for foodproducts.

8. Test tolerance variances. Look at what your container and closure suppliers areproviding in terms of both the widest and narrowest tolerances. Test the opposite extremeswith one another and see how the machine handles it. Youll obtain valuable insight into howexible the machine will be with borderline materials.

9. Test known bad inputs. Deliberately feed in the wrong container and thewrong closure. This is known as induced failure testing. This is part of trying to simulatewhat happens on the third shift, when operators may be tired and not as aware of their

surroundings. What happens if material is loaded in the wrong way? If operators load thewrong caps? Will that break the capping machinery? Better to nd out before you buy.

continued

Nine best practicesfor selecting cappingequipment



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In-line cappers versus rotarychuck-style cappersIn-line cappers are traditionally cheaper than rotary chuck cappers, which can cost up to 10times the price. In-line cappers will typically have a smaller footprint than a rotary machine. Inmany cases, an in-line machine can be mounted over an existing section of bottle conveyor.Finally, in-line cappers typically have lower costs for the additional change parts required to

run different sizes of containers and closures.

Rotary chuck cappers have much higher speed capabilities than in-line machines. Chuckcappers can be supplied with as many as 40 heads that operate at production speeds fromas low as 10 bottles/min to speeds as high as 1,200 bottles/min. (In-line cappers are typicallyspeed-limited to a maximum of 200 bottles/min. In-line cappers are limited in the diameterof cap that can be dependably appliedtypically 28 mm to 70 mm. An In-line capper willgenerally be limited to applying closures that are round in shape. Chuck-style cappers can

apply round, rectangular, square, oval, tapered, and reverse-tapered caps.


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PRIMARY PACKAGING LINE EQUIPMENT



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Trends in coding/marking forprimary packagingA number of trends are shaping the development of coding and marking equipment forprimary packaging:

1. Better integration capabilities. While equipment controls have remained

relatively the same, machines have evolved to integrate more effectively across thepackaging production enterprise, particularly to ensure that coding on the case ties intothe package itself.

2. Triumph of the visual. Not only has packaging become more graphic (see point 4,next page), but coding equipment has also. Coding suppliers are incorporating better and morecolorful touchscreens to help simplify operation, improve productivity, and maximize control.Even ink containers have become more visual: In many cases, bottles have given way to self-

contained cartridges that have meters for easy and more accurate visual assessment of levels.

3. Designed for traceability. Regulatory pressures at multiple levels continue toincrease the need for products to be traceable throughout the distribution chain. The foodindustry has taken the lead in this effort with the adoption of the Produce TraceabilityInitiative; it includes an action plan to achieve whole-chain electronic traceability by the endof 2012. Other industries, most notably pharmaceuticals and CPG, are likely to follow suit inthe near term.

BY MARTY WEIL

Source: Domino



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C G G QU


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continued

Trends in coding/marking forprimary packaging

4. Customer-driven standards. The requirementsthat coding and marking equipment must meet are beingdriven less by manufacturers than by the customers ofmanufacturers, such as Walmart, Target, and Costco. Theway manufacturers are implementing coding and markingequipment depends on their customer mix.

5. Response to harsh environments. In harshenvironments, there is greater variance in stainless steelon bagger machines, but in environments with causticchemicals, stringent stainless grading is the rule. Also,better bracketry is being used, along with print rollers thatare food-grade acceptable.

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Ten tips for buying coding/ marking systems for primarypackagingEven for packaging veterans, coding and marking can be tricky. The equipment is high-techand high maintenance. It requires an extra dose of operator training, advanced cleaning

techniques, and the willingness to periodically update capabilities and analyze theireffectiveness. The following practices are recommended to those specifying new or upgradedcoding and marking equipment for primary packaging:

1. Know your operation. Careful analysis can make the difference between a successfulcoding installation and one that experiences needless downtime, resulting in unhappycustomers. Once you know these factors, it will be easier to choose which marking and codingtechnology is best for your application. Key factors to consider include:

Types of materials or substrates youll be marking

Desired speed of application or throughput

Print quality: permanence and readability

Up-front investment your company is willing to make

Source: Domino



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Q


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continued

Ten tips for buying coding/markingsystems for primary packaging

Whether variable data, graphics, and bar codes areneeded

The distribution cycle characteristics for your packaging

2. Find room on the package, and room onthe line. Make certain an area of real estate on thepackage is available and accessible to coding and markingequipment during the packaging process. To accomplishthis, make sure your packaging line OEM works withyour coding supplier early on to ensure all the necessaryrequirements for integrating the marking and coding

equipment are considered. Too often, marking and codingis an afterthought in the line layout, and packagers ndthemselves scrambling to nd an area on the package tomark the variable information, like date and lot number,and an accessible area of the packaging line to accept themarking and coding equipment.

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3. Know your coding options. Ink-jet doesnt work for logos on a primary package.Some types of ink-jet technologies dont do bar codes well; use thermal transfer insteadfor bar-code applications. Specify to the vendor the grade, printing substrate, and printingapplication. Fully understanding the application will reduce costs and increase codingefficiency. On-demand or preprinted labels? Preprinted labels work for operations that havea volume of identical labels with many colors or complex graphics, because this option savesboth time and money. However, to be exible and responsive to operational changes, on-demand labels can provide a solution for those with variable data.

Ink-jet, laser, or thermal printing? Ink jet works well for printing cartons and productpackaging, but is not necessarily ideal for all bar-coding applications. Laser printing worksfor some bar-code applications, but requires an area to be printed on the label (assuming a

white label) that can be burned off to leave the variable informationbehind. Its higher up-front costs (compared to ink jet) are offset bythe fact that laser printers run longer without issues, are cleaner, andhave almost no moving parts. Direct thermal is a simple process thatworks well with printed labels that have a short shelf life and are not

exposed to heat, sunlight, or rough handling. Thermal transfer canhandle heat and moisture as well as the vagaries of shipping andthe distribution environment. When looking at the options, dont just consider cost of hardwarethink about costs of supplies andconsumables as well. If you are presenting a prospective supplierwith a challenging application, an online demo of the equipmentyou are considering is always a wise choice and in most cases willmake your decision much easier.

continued

Ten tips for buyingcoding/markingsystems for primarypackaging

Primary packagingplan to add or switch to these coding methods

Source: Packaging World Reader Survey January 2013

Other (please specify)

Continuous ink-jet (CIJ)

Thermal ink-jet (TIJ)

Laser

Thermal transferoverprinter (TTO)

Print-and-apply labelers

34%

14%

31%

15%

19%

17%



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4. Value versatility. How versatile is the coding system? Are you choosing a exiblesolution that enables quick response to new packaging substrates or congurations? Brandowners understand that new and fresh packaging has a direct and positive impact on sales.New packaging congurations are changing faster than ever. Can your coding system adapt?

5. Realize that no machine is an island. Can the coding system youre consideringbe integrated for improved efficiency? Historically, coding and marking printers have beenpurchased and installed as stand-alone devices. Today, automation and integration is increasinglyimportant for improving efficiencies and as a means of reducing errors. For example, packagers are

networking coding equipment in their plants, both horizontally and vertically. In other words, theyare creating a central command post that manages information not only among production lines,but also among primary, secondary, and tertiary coding systems. The ability to enter a productcode one time and have it quickly download from product to pallet printing stations can savesignicant time and reduce message entry errors. There are solutions available today that offer acoding automation platform that provides a modular approach, allowing entry-level investmentthat can grow into fully automated integrated systems.

6. Find a coding partner. Consider investing some time up front to nd a codingand marking partner and simplify your life. Most plants have multiple brands of printers. This makes managing your printer eet and coding supplier relationships complex. Largesuppliers that can install and service one brand of printers that serves all coding needs (upand down the production line) can make your life easier with coding user interfaces, technicaltraining, and service programsnot to mention one phone number to call for your codingrequirements. Obviously this increases sales for the big vendors, but it provides cost and timebenets for packagers as well.

continued

Ten tips for buyingcoding/markingsystems for primarypackaging


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Comparing coding technologiesContinuous Ink Jet (CIJ) and Thermal Ink Jet (TIJ) are the two predominant ink-jettechnologies used in primary package industrial coding applications. Laser systems, whichhave experienced steady increases in adoption over the past 10 years, are offering a thirdoption in industrial coding applications. Thermal Transfer Overprinting (TTO) has foundincreasing application with exible packaging. Each technology has an inherent set ofoperating considerations. When choosing among them, it is useful to consider the strengths

of each technology.

CIJ strengths:

It adheres to most packaging materials and can be used on curved surfaces, such as thebottom of a soda can.

It is capable of achieving very high speeds for alphanumeric codes.

Many small-character CIJ printers are portable and can be moved from line to line asneeds arise.

The latest generation has signicantly improved reliability with decreased maintenancerequirements.

Source: Videojet


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TIJ printers are inherently clean and easy to use due to their replaceable cartridge

design. As inks become available that are darker and deliver better dry times, andprinter vendors offer more rugged industrial designs, TIJ technology is experiencingincreased adoption.

Laser strengths:

While requiring a higher initial investment, lasers offer high reliability with minimalmaintenance and good print quality. These factors will continue to drive an increased

usage of lasers in industrial coding applications.

It can be used for marking numerical codes, 2D-matrix and bar codes, logos, andsymbols onto labels, sleeves, glass and plastic bottles, cans, kegs, tubes, blisters,cardboards, tubular lms, and caps.

The advantages of laser coding include speed, versatility, code permanence,noncontact operation, clean and dry process, maintenance-free operation overthousands of hours, extremely low operating costs, and adaptability to a fullyautomated line.

Lasers also offer high reliability in no-code/ no-run operations. This means that if itsmandatory to code the product prior to distribution, then production will stop if aproduct is coded incorrectly.

continued

Comparing codingtechnologies

Source: Videojet



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Laser coding vendors are often asked about the difference between laser ablation and lasercolor change. In most cases, the substrate will determine if you need to choose between laser

ablation and color change. Most of the applications of a CO2 laser are laser ablation, wherethe top color is removed, and the color underneath shows through. There are some limitedsubstrates that actually change color when marked with a CO2 laser, with polyvinyl chloridebeing the most common. CO2 lasers are often engraving what they mark, which can slightlyalter the color, as seen with PET bottles. When marking PET bottles with a CO2 laser, the markturns slightly opaque, which allows it to stand out more. That is, the color does not change,but the material reacts to the laser to cause this effect. YAG lasers perform a color change onmost plastics, which is caused by the effect of the 1064-nm wavelength of the YAG laser onthe material to be marked. The best way to determine the optimum laser technology for yourapplication is to provide samples to your sales representative, who will advise you of youroptions.

TTO strengths:

TTO features a thermal transfer print head and ribbon that makes contact with a exible

substrate, such as synthetic lms and plastic labels. Miniature print elements under aglass coating heat small areas of the ribbon and transfer ink to the target substrate.

Print elements are program-controlled to create real-time images, including clean,high-resolution bar codes, text, and graphics.

TTO systems can address applications in both continuous (moving) and intermittent(stop-print-start) environments.

continued




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continued


Primary Packaging - Coding OptionsContinuousInk Jet

Laser ThermalInk Jet

Thermal TransferOverprinter

Comments

Folding Carton 2 1 2 3 Conduct laser sample testingMetal Can 1 3 3 3 CIJ most optimal for this substrateShrink Wrap 2 3 2 3 Consider TIJ and conduct sample testingHDPE Container/Pouch

1 2 2 2 CIJ likely best option (for strong TCO and substrateadhesion), but if laser or TIJ work, this could be a goodalternative

PET Container/Pouch

2 1 2 3 Laser is typically an excellent option

Glass Container 1 2 3 3 CIJ and laser used extensively for glass printingOPP Container/Pouch

1 2 1 2 Generally a difficult substrate to mark

CPP Container/

Pouch

1 2 2 1

BOP Container/Pouch

1 2 2 3 Often limited to CIJ coding

Paper Container/Pouch

1 2 1 2 TIJ may be an excellent option

Coated Foil Pouch 1 1 1 1 Generally there are many coding options for this substrateFoil Pouch 1 1 2 1

It is recommended to conduct sample testing for allapplications and substrates

1 - Best t 2 - Good t 3 - Not a good t



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Typical applications for TTO are within the snack, bakery, meats, and frozen foodindustries, where exible packaging is common. Such packaging also plays a big part inthe retail hardware sector, where items like screws, nails, and ttings for do-it-yourselfprojects are sold prepacked.

Ultimately, when deciding on a coding technology, the strengths of each must be matchedwith how well it will integrate with other equipment on the line. It is critical to matchthe production line communications with printer capabilities, as well as ensure that theprinter has the ability to process the information and print at the speeds necessary to meet

production demands.

continued




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Best practices for specifyingconveying and containerhandling equipmentDespite their importance, conveyors and container handling technologies are often anafterthought. They shouldnt be. Things to consider:

1. Buy the conveyor pre-integrated. When considering a new line, its oftensmart to buy the conveyor as part of the machine. If youre buying a packaging machineas a replacement, it might be tempting to retain the old conveyors, but be aware that thematch might not be optimal, especially at transfer points. If the machinery builder suppliesthe conveyor already integrated, it reduces installation costs (versus purchasing a separateconveyor), installation time, and line commissioning of I/O devices. This will also ensure thatno stand-alone control cabinet is required and that all variable frequency drives (VFDs) and

devices, and the power panel and PLC control panel are assembled onto the conveyor legsand frame. All the information will show up on one screenmotors, alarms, and controllersmaking things simpler for the operator, technicians, and engineering staff.

2. Understand how your containers behave. You need to consider packagegeometry, center of gravity, and mass when specifying conveyors. For example, emptyPET bottles act differently under pressure compared to lled bottles; hence the conveyingand container handling has different requirements on different stages of the line. Fully



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understanding your package geometry can also help you avoid excessive back-pressure.When youre feeding a product, excessive back-pressure can force a package into a machine

before it is ready. Whether youre feeding, sorting, or unscrambling, back-pressure values are alldependent on the dimensional stability of the package; so, you need to completely understandyour package or container spec when asking a vendor to design a starwheel or a timing screwaround the package. Everything depends on form and shape. Starwheels are good for certainshaped containers, whereas timing screws are often better for rounded containers.

3. Realize that its all about control of the container. Conveying is rarely, ifever, just free-owing product or containers. Proper spacing, position, and orientation mustbe maintained. The goal is to ensure that product ow can take place within a given footprint.Conveying is not just a means to get something from one machine to the next. You mustunderstand what the next machine can handle. You need to understand the following:

Whether container control may best be achieved by single-le or mass conveying

How many lanes should be used

Where is the optimal speed

How to maintain control at the desired speeds with an unstable container

Whether the container needs to be controlled by the neck or the base

continued

Best practices forspecifying conveyingand containerhandling equipment


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Whether or not control can be maintained if something downstream breaks andconveying systems stop

Is there adequate clearance and access to easily clear a conveyor of jams? Or will thingsslam into each other, lock up your machines, and stop your line? Slower speeds maymean a higher chance of success.

4. Carefully consider unique features and options. Some conveyormanufacturers offer a simplied change of direction, having integrated features into

conveyors that turn packages at a 90-degree angle. Its done with rollers in the conveyormat top, and you can adjust the direction of the turn to your specic oor space. Similarly,some engineers prefer to have VFDs on every conveyor. Its a great feature, but sometimesthat extra hardware is an unnecessary expense. Depending on your product, some thingswill never need a change in speed. Think about whether the extra VFDs just add unnecessarycomplexity, or are worth it for future exibility.

5. Pay close attention to friction, cleats, and changes in elevation. Whenconveying unpackaged foodstuffs with vibratory conveyors, it is wise to minimize dropsand stick to a general guideline that no drop should ever exceed six inches. Similarly, whenconveying delicate product, reduce friction by seeking out the most nonabrasive conveyors.If you bounce your product against redirecting plates, as opposed to a soft landing on otherproduct, you will end up with less good product in the box. Timing screws can offer gentlerhandling compared to starwheels, and also tend to be more compact.

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6. Consider a robotic solution to product handling. Product handling can bean ideal robotic application on the packaging line. The most successful applications tend tohave these characteristics:

Where the product comes in randomly or not oriented, and must leave in a specicorientation/order.

Where there is a degree of product variation in size or shape(example: frozen egg rolls/burritos).

Where there is high changeover and plans for totally new products/packages in thenear future.

7. Look for ease of maintenance. The level of technology involved should be afactor in evaluating the equipments total cost of ownership, as it can directly affect thetype of maintenance required, and the skill level of maintenance personnel. A sometimes-overlooked component of good maintenance is spare parts inventory and equipment

documentation. Determining which parts should be kept on-premises can be the differencebetween a short stoppage and an extended one.

8. Put safety rst. Conveyor accidents impact companies in lost productivity, workerscompensation, and even OSHA nes. Safety hazards should be designed out; however, owingto the fact that conveyors have moving parts, there remains an inherent danger. Make useof every safeguard available: Conveyors should have lockouts, guardrails, and other safetyfeatures. Pay attention to operator ergonomics such as easy and quick access to emergency

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T he Experience Mattersconveyor-automation.com

AUTOMATION. IT BEGINS FACE-TO-FACE.

Our approach to custom automation solutions is uniquely customer-centricwith a low client-to-engineer ratio, a culture built to tackle your toughest challenges and a production processthats virtually eliminated change orders. The result is an experience you wouldnt expect,and results you never thought possible. So for turnkey solutions to complete linedesign and upgrades to existing lines , make Conveyor & Automation your choice.

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continued

Best practices for specifying conveyingand container handling equipment

stops and speed controls. Not every aspect of safety,however, can be factory-ordered. Your company shouldhave safety policies that include employee training. Thereare federal government-compiled statistics on industrialaccidents, categorized by type of equipment. Its a good

reference source to assure that employee training, at thevery minimum, addresses the most common causes ofconveyor accidents.

9. Pay attention to sanitation. For food-contactapplications, pay attention to sanitation and cleanability.If youre trying to remove cross-contamination betweenproducts, make sure the conveyor belt design doesnt trapparticles. For food, beverage, or pharma applications, lookfor conveyors with a minimum of nooks and crannies thatcan harbor bacteria and dirt. Verify that if the conveyingchain is swabbed, it removes 100% of the product. (Thatwill be especially important for compliance with the FoodSafety Modernization Act.)


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Best practices for bufferingand packaging line designWhether or not to buffer a packaging line ranks right up there with Total Cost of Ownership asone of the most divisive issues pertaining to automated packaging lines. We talked to expertson both sides of the debate, and came up with the following considerations that can helpkeep your lines moving:

1. Use buffering to add value, not cover weaknesses. Buffering isnt intendedfor convenience, or to cover weaknesses in line ow and speed. A buffer may be hidingperformance issues upstream or downstream.

2. Higher line speeds require more buffering. The higher the line speed,the more likely buffers will be required, precisely because the cost of downtime increasescommensurately with the number of packages produced per minute. On a line moving 60

items/min, no buffering is typically needed because people can physically offload product toa cart. At around 100 products/min, it may be necessary to install a buffering solution.

3. Buffering smoothes out certain processes. Buffers may also be required forprocesses that take time, such as drying packages emerging from a water bath, evacuatingair from pouches before lling, or the strict dwell-time and temperature standards of heatpasteurization.

BY PAUL ZEPF


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4. Buffer to close gaps caused by intermittent motion. Indexing machinesand batch processes with gaps in their motion or ow may require buffers, as opposed tothe steady stream of continuous processes. Remove bottlenecks by using buffers to mitigateintermittent gaps in ow.

5. Transition from processing to packaging. Some form of accumulation maybe necessary to accommodate quality checks before products are released to packaging.Limiting the number of items on the line at quality checkpoints, however, helps keep thefocus on process improvement with minimal accumulation.

6. Consider redundant machines. In an operation where time is money, the cost ofredundant machines may be lower than the losses that result from shutdowns. One optionis to use some sort of bidirectional mass-ow buffer; another option may be to install, forexample, two labelers running at 50% capacity and split the ow. If one labeler goes down,the other can handle the full ow.

7. Find the lines sweet spot. Some lines run best at breakneck speed; others are

most efficient at a slow and steady pace. Practitioners of the manufacturing and packagingart often make the mistake of setting speeds too high, too close to design specications. Onefailure can be disastrous to productivity. Installations vary, but trial and error become evidentwhen you document your results to arrive at the optimal combination of speed and productquality on a balanced line with minimal upsets or downtime. Trained personnel can choosefrom a wide array of statistical analysis tools to arrive at the right speed for your equipmentan

Documents

Playbook Primary Pkg Mc 2013