The packaging industry is caught between contradictory demands. It must be profitable while operating in an environment that requires it to produce more and more. At the same time, it is expected to make the necessary efforts with regard to its environmental responsibility, and therefore review all its processes and update its raw materials. Individually customisable packaging, 100% recyclable, even compostable or edible: the sector absolutely needs to be redesigned. And this task calls for high-performance machines, as packaging is always essential for brand communication and launching new products.
The sector’s good health therefore comes with major industrial issues: the packaging world needs solutions that offer greater profitability and meet environmental requirements.
Access to high-performance machinery
Machinery in the packaging sector is constantly evolving. Even so, many companies can’t keep up with the changes because of the costs involved. Given that profitability lies in production speed, drive motors are above all where developments can be the most substantial – and, at the same time, the least expensive compared with a complete change of equipment.
Compact, efficient motors
Increasing the speed and profitability of production lines means being equipped with automatic packaging machines with compact and high-performance drive. For example, in their standard version, brushless IDX motors have an integrated positioning controller, resulting in an automatic adjustment. These compact drives offer a nominal permanent torque of 794 mNm and a nominal speed of 6000 rpm, giving them a high power density (308W). In addition, there is a very short delivery time (around 4 weeks).
As a result:
• Your packaging machinery performs better in terms of production speed and requires little maintenance,
• Your delivery times are shortened,
• Our IDX systems understand your machinery’s common communication buses, which optimises your development cycles.
Perform maintenance remotely
Remote maintenance on industrial machines has taken on a new dimension with the IoT (Internet of Things). However, the communication buses that precede and extend them already allow the motor driver and the controller – a computer or an automated system – to communicate.
In its traditional form, in production units, it is common to program the management of machines and their motors remotely, especially through an Internet connection. With the addition of smart sensors, it is now possible to perform conventional maintenance remotely as well as predictive maintenance. Data is collected in the interests of minimising breakdowns. In both cases, remote maintenance reduces the risk of production shutdowns and therefore lost profitability. This is possible for both the technical components of the machine and its motor.
In addition, thanks to the CANopen and EtherCAT communication buses, the adjustable digital and analogue inputs and outputs can be adapted to many device profiles. Furthermore, intuitive commissioning software is provided, just like free libraries.
Choosing motors that adapt to the existing environment
innovations require changing all your machines. This generally isn’t an option in the industrial sector, where machinery depreciates over the long term. To avoid making this choice and cutting profitability, it is possible to integrate new motors into existing installations.
So, no matter what solution you are currently using, the IDX range is modular (front flange, cabling, definition of the axis, etc.) on our online configurator and can adapt to your existing machinery.
Flexible, innovative, eco-friendly machines
Environmental concerns are forcing the packaging industry to reinvent itself, particularly through the use of more eco-friendly materials (less energy-intensive, more easily recyclable). That being said, manufacturers are now incorporating recycled plastic into their production lines and are particularly invested in research and development to find alternative solutions.
To meet the demands of a dramatically changing market, the packaging industry relies on machinery with flexible, customised motor systems, enabling it to change its processes more easily. To this end, several factors must be taken into consideration:
• Being able to test motors quickly: IDX motors are delivered within 4 weeks, compared with the usual market average of 19 weeks. This point is also crucial for machine maintenance. Delivery is fast, and the modularity of the motor is essential. It is therefore a competitive solution.
• An internal temperature control is vital for an actuator like the IDX which is designed to be operated in overloaded condition for a limited period of time during a motion cycle. The IDX prevents its motor winding and electronics from damage by internal temperature sensors and an automatic derating or shut-down. Configurable continuous and peak current limitations in addition enable the machine builder or operator to adjust the output torque based on the application’s requirements.
• The IDX offers a high-performance CANopen or EtherCAT bus interface which is commonly in use by PLCs for dynamic commanding of the drive plus gathering process data on the fly. There is an additional USB port present for easy initial commissioning or testing by maxon’s EPOS Studio software. It is even possible to command the IDX by CANopen or USB by Windows or Linux system environments (e.g. PC, Rapsberry Pi) and maxon’s “EPOS Command library” if no real-time data exchange is required by an application
The packaging sector is now at a turning point in its history. More than ever, companies need high-performance machinery that meets quality and productivity requirements. maxon is developing ever more powerful and reliable drive motors to respond to the changes in the sector. As always, maxon is attentive to the needs of its customers.