Automation on three levels with Syntegon Operator Assistance

Streamlining case packing: the bold moves of automation

Display packaging is what first catches the consumer’s eye on the supermarket shelf: bold colors, bright fonts and a vast array of shapes and sizes – an ever-expanding variety that brand owners of different industries need to cater to. For many food manufacturers, automating their lines to incorporate higher pack style flexibility is the answer to meeting the industry’s increasing flexibility demands while keeping case packing processes efficient. That is why Syntegon’s Elematic 3001 WAH case packer now comes with Syntegon Operator Assistance – a feature that allows for fast and error-free changeovers with varying degrees of automation. In combination with additional quality control features, manufacturers can minimize downtimes, increase availability, automate process monitoring and ultimately maximize efficiency during case packing.

Ramping up the automation level of one’s packaging line is one of the biggest levers manufacturers can apply to improve their productivity. The more process steps are automated, the faster and smoother they run. During case packing, where format changes are frequent, these efficiency benefits are particularly apparent: Higher levels of automation allow operators to leave repetitive manual tasks – such as format changeovers – to the machine to perform them error-free at high speeds – ultimately making them more cost-efficient.

That is why Syntegon’s Elematic 3001 WAH case packer can now be equipped with Syntegon Operator Assistance. This feature allows manufacturers to perform format changeovers with three different levels of automation: Guided, verified and semi- automatic format changeovers. They can be used in combination with each other or implemented independently. This flexibility allows manufacturers to choose the level of automation that fits their requirements best. No matter which changeover feature they decide on, the integrated HMI module guides operators through the changeover, making the process clear and easy.

Automation level 1: Guided Size Changeover

During guided changeovers, the HMI and Message-in-Place-screens indicate which individual format parts need to be changed and which Elematic Click settings need to be adjusted. Operators receive step-by-step instructions on the Message-in-Place-screens located directly at the respective format points. To increase the visibility of due tasks, LEDs integrated in the screens indicate the location of each task.

Automation level 2: Verified Size Changeover

By opting for verified changeovers, manufacturers can include automatic verification of each setting and format part via RFID technology for traceability and error-free changeovers – avoiding production disruption and downtimes. Additionally, Verified Size Changeovers can be combined with Guided Size Changeover for an automatic confirmation of each task, which further increases efficiency.

Automation level 3: Semi-Automatic Size Changeover

Semi-automatic size changeovers allow for the highest level of automation in case packing: Motorized format axes enable smooth and near-instant simultaneous adjustment of multiple changeover settings at once, so operators can process a variety of formats and sizes at the touch of a button on the HMI module.

Proven safety and automated quality control features

Optionally, Syntegon’s Elematic 3001 WAH case packer is equipped with a number of features to ensure optimal quality control and efficiency. An integrated light curtain at the outfeed provides protection against reaching into the machine on a minimal footprint, while a checkweigher performs one last quality control check before the case is loaded. The container for glue pellets is fully integrated into the machine, thus saving space on the production floor. To make sure that all these automation features can deliver optimal results, the case packer is designed for seamless line integration.