Packaging Line Integration is crucial to the operation and overall efficiency of any production line. There are many factors which need to be considered when integrating a packaging line. Some of the most important ones are: available floor space, required throughput speeds, proper spacing between machines, future expansion and work flow of the packaging line. Modular incorporates years of experience integrating packaging lines coupled with our unique components to make each integration a success.
Design of the Packaging Line:
Integration of the packaging line will start with a site visit and a comprehensive review of the packaging suite. Using the information obtained from the site visit, Modular will engineer a system to meet the production requirements and allow for proper work flow in the room. An example of a 3D room layout is below.
Modular Integration products include the following
Container Handling Equipment
Conveyors, Sanitary Style (raised bed) Stainless Steel:
4” width (any length in 1ft increment)
7.5” width (any length in 1ft increment)
12” width (any length in 1ft increment)
One to Two Lane Dividers and Two to One Lane Combining Systems: These systems can be added to the 7.5” and 12” wide conveyors above and are often used when mounting two or four electronic counters to a single conveyor. Incorporating its own PLC controller and HMI, these systems can be used as a “stand-alone” system for many different packaging operations.
Conveyor Cross Overs: Used to transfer products between two conveyors running parallel to each other. Our crossovers are made of clear poly-carbonate for visibility. These units are designed for fast repeatable changeover.
90 degree turn discs: These 12” turn discs are attached to independent motors and are mounted to the end of our conveyors with adjustable guides to allow product transferred at right angles to another conveyor.
Feed / Infeed Table: 36” unit with a loading tray introduce product to the beginning of a packaging line. (48” version available as well).
Surge Table: 36” unit which is often used for accumulation between induction sealers and retorquers or before labelers to allow time to change the roll of labels. (48” version available as well).
Bi-Flow Table: Modular can also provide accumulation tables or bi-flow tables used in buffering containers along the packaging line.
Accumulation Table: 36” unit used to accumulate containers at the end of the line to facilitate the operator’s ability to “pack-off” the containers into cases or the next packaging operation.
Metering / Pacing Wheels: These units create space between containers for various operations and are mounted to conveyors with their own independent motors and controls.
“Back-up” Sensors: These sensors are used to identify line stoppages which would in turn pause the pacing wheels or other devices to keep product from interfering with other packaging operations. They are often used in conjunction with the Line Management System, but can be added independently as well.
Line Management System is a system comprised of a separate HMI and PLC controller to aide in the movement of containers along the packaging line. This system controls container flow by monitoring its movement at various points along the packaging line. Based upon the feedback from these monitoring sensors, containers can be started or stopped along the line to maximize throughput and eliminate bottlenecks. This system is also capable of product specific recipe downloads and will provide OEE information for the entire line as well as for individual components on the packaging line. Packaging suite statistics can be monitored remotely and can serve to set production goals for line operators. Modular can tailor a system that meets your project requirements.
Utility Distribution allows each packaging line to have one main pneumatic and electrical connection point. Power is then distributed to each of the components along the line. These utilities run through wire ways or troughs which are located below the conveyors and have isolated areas for electrical wires, control wires, and air lines. These troughs are equipped with quick removal covers which allow easy access for maintenance. The trough system can also be equipped with 110V convenience outlets for powering additional equipment along the line.
OEE (Overall Equipment Effectiveness) System can be added to the Line Management System above and is able to track line efficiency. We have simple systems to track overall Line Efficiency and systems which can drill down to each packaging components effectiveness. This information is used to review and improve the throughput and up-time of the entire packaging line. It can also be accessed remotely when networked via web browser.