PD_Packaging Digest

Packaging Digest, April 2013

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www.PackagingDigest.com APRIL 2013 // BEST PRACTICES Joe Sonderman (left) and Greg Wilke explain features of the Spic and Span bottle. In designing the high speed line, ATI first established the operational requirements for each piece of equipment on the new line and then used another Lean tool known as 3P (Production, Preparation, Process), which required seven different layouts at the outset of the project. Once the equipment was selected, the 3P Team literally placed full-size corrugated cutouts of each piece of equipment on the floor to determine the most suitable line layout. "Tis let us get a good idea of how the equipment would fit in the room, and how accessible it would be for the operators," says Greg Wilke, who was the project manager for the installation and is now the production leader during start-up for the new line. Te result is an efficient high-speed packaging line that is operated by only three people. "Flexibility is one of our strengths, so the new line needed to be capable of running different bottle styles and closures," says Joe Sonderman, svp of operations. "Changeover was a paramount concern, because we have to get in and get out of different products in a timely manner." A major change that was instituted for the new line was that processing and packaging are in the same room, though they are in separately defined areas. "We have always located processing and packaging in separate rooms, but this new arrangement allows close interaction and effective communication between blending operators and line operators," says Sonderman. Dedicated line integration As the planning for the new line progressed, systems integrator Advanced Packaging Integration became a key contributor. "We were initially contacted to bid on the robotic palletizer," says John Vaninger, vp-operations, "but as we got more involved in the project, ATI realized that we could do a lot more for them than the robotic palletizer." Advanced Packaging Integration provided the systems integration, supplying all of the conveyors and supplying the controls integration. Changepart storage protects and delivers With the multitude of containers that are run on the new line and more that will be added, storing and keeping track of the changeparts for all of the equipment loomed as a significant challenge. Ingeniously, ATI installed a Shuttle XP500 vertical storage unit with 38 shelves from Kardex Remstar LLC to store all of its changeparts. Horizontal shelves are arranged vertically along the front and back of the unit. When the item on a shelf is required, the shelf is moved onto a belt system that transports it down the center of the unit to the opening at the front, where the item is automatically presented to the operator. The Shuttle XP is a fully automated system. When an item is first placed into the unit, the operator identifies the tray number on the control panel and the system remembers the location. To retrieve an item, the operator enters the item name, and the system automatically retrieves it. The plant uses carts to move the changeparts between the storage facility and the equipment on the packaging line. An automated vertical storage unit, with 38 shelves, stores all of the changeparts for the new line. To retrieve an item, the operator enters the item name into the HMI, and the system automatically delivers the appropriate tray to the delivery space. "The Kardex system has worked out very well for us," says production leader Greg Wilke. "It doesn't take up much floor space for the amount of storage it provides, and it allows us to easily keep track of all of the changeparts. Also, it eliminates any damage that might occur if the parts were sitting out on racks." 23 Monobloc filler/capper includes a 30-head mass flow filler and a 12-head capper. The filler incorporates Coriolis technology that achieves +/-1g fill accuracy. "ATI had a definite idea of what they wanted in the new line," says Vaninger. Tey wanted a U-shaped layout with the operators in the center. Because they are a contract packager and have to be able to run a variety of packages, they wanted the line to be as flexible as possible and require minimum changeover time. Among Advanced Packaging Integration's tasks was to integrate the entire packaging line and the development of the controls. "We integrated all of the machines into one main processor and common HMI, which monitors the status of each machine and displays the status of each machine, as well as the OEE (Overall Equipment Effectiveness), on the 60-inch overhead LCD scoreboard," says Vaninger. Each machine has its own dedicated controls and HMI, but these are also integrated into the main system. Advanced Packaging Integration designed and built all of the conveyors along with required line devices that monitor bottle movement throughout the system. All of the bottle conveyors are equipped with quick-change guide rails to reduce changeover time, and all case conveyors are powered by 24-volt DC motors to minimize noise and energy costs. Multiple vision systems were installed throughout the packaging line to ensure product quality at each stage of the filling and packaging. Tese are included at the exit of the unscrambler to ensure the bottles are oriented properly, at the exit of the labeler to ensure that no labels are missing and that labels are properly oriented, after filling and capping to ensure proper filling level and that caps are in place and are not cocked and after the case packer to ensure that cases are filled. Cognex supplied the cameras, and the controls are AllenBradley from Rockwell Automation to provide a common platform. Running 22-oz Spic and Span bottles During Packaging Digest's visit, the line was running a 22-oz Spic and Span bottle with a handle and a trigger closure at a rate of 150 bottles/min. To start this operation, PET bottles are loaded into the floor hopper of a Posimat Posiflex 30-VA bottle unscrambler. Te bottles are lifted to an overhead Continued on page 24 magenta cyan yellow black ES220888_PD1304_023.pgs 03.27.2013 01:58 UBM

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