Machines, like humans, don’t speak the same language or operate in the same way without external factors influencing and helping them. In the case of machines, automation is the glue that helps them interact and work together. In essence it provides the language that helps them to work in-sync.
Automation is an essential component in the development of Tetra Pak processing and packaging solutions, particularly with our integrated, system approach, where we focus on system performance, productivity, quality and cost effectiveness.
We have several hundred automation, IT, electronics and mechatronics experts in the company. My role focuses on embedded solutions, the control systems that manage our packaging systems. This includes communication technologies, which enable our processing and packaging machines to talk to each other and work together seamlessly for the benefit of our customers.
Automating a production line makes production faster, more efficient and increases consistency, thereby limiting the potential for human error. This offers huge customer value because time equals money and automation provides time and accuracy gains, which positively impact a customer’s bottom line.
In addition, as technologies have evolved, automation has become even more efficient.
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The changes since Tetra Pak first introduced automated solutions in the 1960s have been significant. Automation has evolved from analogue processes, which are dependent on people for information management, to digital processes, which – with the increase in processing power – enable the collection of enormous quantities of data. With this data, we can monitor such things as downtime, wastage and overall equipment efficiency, and that enables us to better advise our customers on how to optimise their manufacturing process.
The increase in processing power and the evolution of the ethernet for local area networks enabled seamless integration from single sensors to increasingly high-level systems that were integrated into software for ERP (enterprise resource planning), MES (manufacturing execution systems) and CMMS (computerised maintenance management systems).
The field is in constant evolution, which means we need to keep abreast of developing technologies and, at the right moment, adapt them quickly to our operations in order to provide a solution that will work for the benefit of our customers. To do this, we have 25 specialists in sensing technologies, line integration, data collection, user interface, control systems, industrial computing and mechatronics.
The Tetra Pak A/3 Speed iLine is a great example of the impact of innovative automation solutions. This line integrates our Tetra Pak A/3 Speed filling machine with distribution equipment and, as a result of line automation, optimises the interaction between all components of the packaging line, improving overall performance and ease of use.
At the heart of the automation platform is the Line Controller 30 (LC30)—a first for aseptic carton packaging. The LC30 automates the interaction among all components of the packaging line, offering enhanced line control and supervision, ease of operations in packaging line management and improved line performance, increasing flexibility.
This high speed line offers the highest package output in the industry – 15,000 family packs/hour and 24,000 portion packs/per hour – without increasing operational costs, translating into significant improvements in production costs
The next step in automating our lines was the iLine XT. This solution enables palletisers, pallet wrappers and laser guided vehicles as well as printers and labellers for distribution units to be integrated into the packaging line thanks to the Line Controller 30 Plus.
Operations can also be integrated with customers’ enterprise resource planning (ERP) systems. And, when used in conjunction with Tetra PlantMaster, iLine XT enables integration with processing operations and interfacing to customer warehouse management systems
iLine XT brings to producers new levels of control like the ability to oversee and control the line set up from one location and use real time dynamic feedback to manage priorities across different lines. It delivers flexible palletising patterns, fast change-over between different product formats and pallet configurations, increased pallet stability and pallet wrappers that pre-stretch film to deliver up to 30 per cent reductions in wrapping costs. In addition, iLine XT marking solutions allow simple, secure and end-to-end package traceability.
Printers and labellers are fully integrated with the production line, identifying the package, multipack, tray and pallet, while automatic data management ensures there is no risk of coding errors.
A huge challenge we had with developing the iLine was to find a way to control all the equipment in order to optimise the best output in operational performance and quality for the line as well as reducing unnecessary downstream over-capacity, which increases the wearing of parts as well as the risk of stoppages.
As such, all machines need to work in-sync and respect the way that they work in an integrated line. The solution was to organise all of the machines in the line according to the speed and capacity of the filling machine, the primary piece of equipment.
The great thing about automation is that we are able to adapt the speed and capacity of the line to accommodate for any changes, such as delays, stoppages or errors that occur on the line. For example, if there is a stoppage downstream on the production line, the accumulator starts up to prevent the filling machine from stopping. Once the problem is resolved, the line will increase its capacity and run faster, which in turn will limit the impact on the production output.
Automation allows our machines to speak the same language in these situations and act as one continuous process so that if one part stops, the other part picks up and supports it until the problem is resolved – all automatically.
The value this synergy brings to customers is huge. Firstly, the automated devices respond quickly based on immediately available data, eliminating subjective, often inaccurate judgements that people can make, particularly when under pressure.This increases accuracy and consistency and reduces the number of operators needed to run the equipment.
Our iLine packaging solution is also equipped with our packaging line monitoring system (PLMS). This is a data management system we developed to enable our customers to monitor the performance of their lines.
This programme monitors and shows data related to downtime, wastage, stoppages, critical control points and quality parameters. This really brings to life the saying ‘knowledge is power’ as with this data customers can make better decisions about their production line(s), respond faster to issues and optimise the performance of their machines.
These are just a few of some of the innovations in automation that we have achieved.
Automation has been around for decades and I expect it to be bigger and better in the decades to come. Today, we still need people to identify when machines need maintenance, but tomorrow machines will tell people when this is needed. The intelligence of automated solutions is increasing as is the customer value that can be derived from it.
While machines are getting more intelligent, we must remember that behind every good machine and technology is a strong team.
Paolo Scarabelli is manager embedded solutions, technologies & service products at Tetra Pak.
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