Pw2015 Primarypkg Playbook v2 Opt

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packager’s playbook serieseducation for packaging professionals

2015EDITION

¾ Coding trends for primary packaging

¾ Coding survey results

¾ PackML and when to use it

¾ How to compare machines at a trade show

HOW TO SUCCESSFULLY IMPLEMENT PRIMARY PACKAGING LINE EQUIPMENT

PLAYBOOK


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packager’s playbook serieseducation for packaging professionals

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SPONSORED BY

ENGINEERED FOR PERFORMANCETM

REA REAL DEMANDS. L SOLUTIONS

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PRIMARY PACKAGING LINE EQUIPMENT PLAYBOOK

CONTENTS

5 All the packaging experts who contributed to this Playbook

7 Your Playbook for building a better packaging line

10 Five trends in liquid filling equipment 13 Nine tips for buying liquid filling equipment 16 Best practices when implementing weigh/filling equipment 19 Key implications of FSMA for food packaging suppliers

25 Auger filling equipment trends and buying tips 29 Nine best practices for selecting capping equipment 32 In-line cappers versus rotary chuck-style cappers 34 Trends in coding/marking for primary packaging 36 Ten tips for buying coding/marking systems for primary packaging 41 Comparing coding technologies

47 Best practices for specifying conveying and container handling equipment

CONTRIBUTORS

INTRODUCTION

EQUIPMENT STRATEGIES


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CONTENTS

88 Ten financial justifications for new equipment 92 Best practices for specifying packaging machinery

98 Vendor evaluation methodology for packaging equipment101 Tips on finding the right equipment supplier 106 Seven tips for comparing machines at a trade show109 Roadmap for a successful Factory Acceptance Test115 Eleven tips for a successful packaging line start-up120 Benefits of PackML and when to use it on your line

123 How projects fail: 11 pitfalls to avoid

PROJECT STRATEGIES

EQUIPMENT STRATEGIES CONTINUED

52 Best practices for buffering and packaging line design 56 How to calculate Overall Equipment Effectiveness: A practical guide 70 Trends and drivers for machine vision technology 76 Best practices in specifying vision systems

79 Metal detection, X-ray, and checkweigh trends81 Best practices in specifying inspection systems85 Trends and tips for specifying induction sealing equipment


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CONTRIBUTORS

Sunny Ishikawa

Engineering Research FellowWrigley

Glenn Whieside

Packaging Engineer, CPP

Synthes (USA)

Dave Hoenig

PrincipalDH Technical Consulting, LLC

Paul H. Davis

Project EngineerRyt-way Industries, LLC

Roy Greengrass P.E.

Senior Engineering ManagerDel Monte Foods

Paul Zepf

P.Eng., M.Eng., CPPZarpac Inc.

San Walulek

Vice PresidentMichel’s Bakery, Inc.

Greg Flickinger

VP Manufacturing and Corporate Engineering,

Snyder’s-Lance, Inc.

Shawn French

Engineering ManagerSun Products

Mathew Couresis

Packaging Dept. Supervisor

Boston Beer

Adam Pawlick

Director of PackagingBay Valley Foods

Paul Redwood

Senior Research Engineer

Church & Dwight

The following brand owners, consultants, and engineering experts contributed to this Playbook:


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CONTRIBUTORS

Serling Anhony

Consultant

Tommy Lancaser

Chief Operating Officer

Bryson Industries

Curis Wardaugh, P.E.

PresidentMedalist Engineering, P.C.

Several other brand owners wereinterviewed for this Playbook onthe condition of anonymity.

Additional Contributors: We gratefully acknowledge the expertise

of these supplier contributors:Accutek, All-Fill, Apacks, Axon, Cognex, Cozzoli Machine Co./MRM/Elgin,Delkor Systems, Domino, Douglas Machine, Econocorp, Fanuc Robotics,Fowler Products, Griffin-Rutgers, Heat & Control, ID Technologies, Lion Precision,MGS Machine, Morrison Container Handling Solutions, Nalbach Engineering,Optima-USA, Pearson Packaging Systems, Spee Dee Packaging Machinery,

Thermo Scientific, Videojet, Weighpack, Yamato, Z.I.T.O. (Zito Induction TechnologyOptions)

Elizabeh Barr FawellAssociate, Food and Agriculture GroupHogan Lovells US LLP


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INTRODUCTION

Your Playbook for buildinga better packaging line

Specifying and installing a modern, automated packaging line is essentially an exercise in

team building. You may be in your present position because of your technical knowledge and

experience, but packaging line experts have told us over and over that good communication

skills—within your plant and outside of it—may be just as important to the success of your

new or upgraded packaging line. You must know your product and your line—and be able tocommunicate that knowledge to both internal and external members of the team. Learn what

package machine builders need to know in order to give you the solutions you want.

The idea behind our Playbooks is the creation of one source that spells out all the tricks and

tips associated with buying, testing, commissioning, and starting up packaging equipment.

To unlock these secrets, we spoke with or consulted with dozens of sources. Most of these

consisted of in-depth phone interviews with experts in the field—engineers and managers at

leading consumer packaged goods companies.

We also talked to suppliers, which gamely set aside their “sales” hat and spoke honestly about

best practices and pitfalls to avoid. Remember that while you may buy one filler or inspection

system or coding/marking system in a given year—if that many—the companies selling that

equipment have been through dozens of projects in that same time period. Learn from their

experiences.

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INTRODUCTION

In short, what you’re reading is the collective thinking of an industry, representing hundreds

of years of packaging experience, distilled into a short, actionable, bulleted style that makes

for easy reading.

This particular Playbook, like our other successful Playbooks in the areas of flexible packaging,

labeling, and package development, has been updated for 2013. The Primary Playbook covers

the front half of the packaging line—from unscrambling through induction sealing. New

material in the areas of weighing/filling, robotics, and primary coding has been added to

bring these subjects up to date.

You will also want to download the End-of-Line Equipment Playbook, which covers

everything on the back half of the packaging line, from cartoning, case packing, and shrink

bundling through palletizing and stretch wrapping. The two Playbooks will equip you well for

your next project. (See all our Playbooks at Packworld.com/playbook .) All of our Playbooks are

designed to be read either on the screen, or printed out.

A final word. The entire cost of producing and distributing this Playbook has been

underwritten by the companies that have sponsored it. We thank them for their support, andwe thank you for reading. ¿

continued

Your Playbook forbuilding a betterpackaging line

http://www.packworld.com/playbookhttp://www.packworld.com/playbookhttp://www.packworld.com/playbookhttp://www.packworld.com/playbook/forward/primaryhttp://www.packworld.com/playbooks/comment?pb=Primaryhttp://www.packworld.com/playbook


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INTRODUCTION

Our Editor:

Melissa Larson has been writing about the packaging and converting industries since 1984.

She was senior editor of Packaging magazine, was the founding editor of Pharmaceutical and

Medical Packaging News , and was managing editor of Converting. She has also blogged for

PMMI’s Connected Communities and other packaging industry clients. She resides in Barrington, IL.

Melissa Larson

Contributing Editor



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Five trends in liquidfilling equipment

Speed and precision are the hallmarks of liquid filling systems. As the economy improves,

packagers are under the gun, using all their planning skills to take care of business while

utilizing the equipment already on the floor, and perhaps contemplating new technology.

Here’s what they are discovering is available in liquid filling:

1. Shorter lead times: Short build times are the norm as the economy recovers, as mostpackagers are dealing with multiple product lines, projects, and deadlines. They are searching

for suppliers that can deliver a full packaging line with the shortest build time. Budget is still a

concern, but the growing demands, in particular, of the food and beverage business dictate a

fully integrated solution on a tight deadline.

2. Flexibility and adaptability: Packagers continue to look for flexibility in machineryso they can package products with a wide range of containers, caps, labels, sleeves, and

products. They want machines that can handle different size/shape containers as a standard

feature, without additional add-ons or a custom solution.

3.Quick changeovers: SKU proliferation and retailers that order at the last minute toavoid holding stock have driven the need for faster changeovers in recent years. This has led

to the development of technologies for quicker cleaning, eliminating pistons, cylinders, and

valves that have to be removed, cleaned, and reinstalled. Instead, such components can be

Source: Apacks



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FAST.RUGGED.RELIABLE.

ACCURATE.

www.YamatoAmericas.com(262) 236-0000

COMBINATION WEIGHERS

B o o t h 3 18 2 N o v e m b e r 2 - 5

continued

Five trends in liquid filling equipment

cleaned with hot water or steam straight through the filling

nozzle. On in-line machines, there’s also a trend favoring

universal change parts, reducing or in some cases even

eliminating the need to remove parts for a size change.

4. Compliance with the Food SafetyModernization Act (FSMA): Cleanability per FSMAis a big concern for filler machine builders. Fillers have

a tendency to have complex “fluid pathways” due to the

many pistons, pumps, and check valves inherent in their

design. Cleanability goals are quick disassembly with no

tools needed, disassembly of hoses, etc., and no hidden

fluid pathways.

5. Multiple-function machines: Packagers areasking for machines that can perform multiple functions

beyond that of the traditional monobloc filler/capper. One

example cited was a machine that orients bottles and caps

to one another as well as to the final case-packing system.

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Videojet marking and printing technology is constantly advancing to

deliver more and better codes on almost any package type. From

the printing of simple ‘best by’ dates to GS1 DataMatrix bar codes

for serialization, Videojet delivers solutions expertly matched to your

packaging line.

800-843-3610

www.videojet.com

Code accuracy andprint speeds matter.Trust Videojet.

continued

Five trends in liquid filling equipmentCPGs also want more equipment flexibility to accommodate

a continually expanding range of packaging formats,

including a wider variety of container shapes, sizes, material

structures, and closure mechanisms. Five years from now,

some machine builders predict more complexly integrated

machines with software adaptations that can handle maybe

four to six operations (for example, filling, capping, labeling,coding, cartoning, and casing) in one system. Also predicted

are multiple production cells—if one module fails, you can

take it out and replace it without having to replace the

entire system. ¿

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Nine tips for buyingliquid filling equipment

There are several things to keep in mind when selecting liquid fillers to ensure the right fit for

your application:

1. Understand how the machine affects the product. You need to think about

the impact of the filler on the product you’re packaging. The state or viscosity of the liquid canbe inadvertently changed, based solely on the construction of the equipment. For example,

running a liquid through extra elbows, pipes, and pumps can change the viscosity, resulting

in a liquid that is much too thin. High speeds can also impact some products negatively. You

need to keep the product characteristics front-of-mind when selecting equipment.

2. Understand how the product dictates the type of filler. The type ofmachine utilized for a project is often dependent on beverage/product characteristics and the

type and shape of the containers. Free-flowing liquids like beverages work well with a timed-

flow or overflow machine, whereas a more viscous product might be better suited for a piston

or positive displacement (PD) filler. The fill size or type of container might also determine the

type of machine used. Timed-flow and overflow machines are both good for free-flowing

liquids but differ in how they deliver product to a container. Timed-flow fillers are a volumetric

fill machine, meaning each fill cycle they deliver exactly the same volume of product. These

Source: Apacks

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machines are designed for very precise fills regardless of the container shape. However if the

container varies in volume, the fill levels may have an inconsistent look. Glass bottles are a

good example of containers that often have varying inner shapes and volumes.

3. Know the filling challenges of handling beverages with pulp or fruitpieces. Pulp or fruit pieces, otherwise known as particulates, require specialized pumpsand valves based on the size and density of the individual particulates. Challenges with filling

particulates arise whenever there is a significant variance in the size of the pieces. Pickles are

a good example of a product that has particulates with a large size variance. Small or soft

particulates are usually easier to accommodate.

4. Look at ease of cleaning. Pay attention to the cleanability of equipment. As withany product destined for consumption, the machine must be made of FDA-approved sanitary

materials. Most customers, including beverage providers, want equipment that is easy to

clean and maintain. When filling bottles, keeping the nozzle clean is of primary importance

to good manufacturing practices. Simpler design is better: Make sure the equipment doesn’t

have nooks and crannies that can harbor microorganisms. Also look for filling machines that

have clean-in-place systems as a standard feature.

5. Lighten up. Plastic bottle lightweighting continues to be a major trend, and with costand sustainability advantages, this trend isn’t going away anytime soon. So be sure to look for

unscrambling and filling technologies that will accommodate progressively thinner bottles.

“Feather bottles,” down to just seven grams of plastic for a half-liter bottle, with a short-skirted

cap, call for kinder, gentler unscrambling and filling.

continued

Nine tips forbuying liquid fillingequipment



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6. Don’t give away product. Don’t accept a vendor giving you a general averagein weight variation. You need to know what that percentage is at the actual container sizes

you intend to run today and in the future. Giveaway can actually vary slightly at different

container sizes.

7. Avoid complexity. Complex fillers equal complex maintenance needs. The simplerthe machine, the less maintenance, the less training, and the fewer parts that need to be

kept on hand. Watch for parts or components that may have the potential to break off. If you

don’t have a screen prior to the fill head or nozzle, pieces of metal or plastic can get into your

product. Even good inspection systems may not be 100% effective in detecting a piece ofmetal or plastic in a metal can.

8. Ask about changeover times. If you know you’re filling different products, orthat you may be someday, you need to know about changeover times. Changeover time

reductions are a key factor in boosting efficiency. The goal is quick, repeatable changeovers,

so you can get your line up and running again as soon as possible.

9. Know what you need today, but have flexibility for tomorrow. Whenselecting a machine, keep an eye on future output. See into Year Two, and think about future

new products and their filling needs. Look vertically across your products, as well as upstream

in the supply chain. What happens if a key ingredient in the formula of your product changes?

Does this mean your nozzles may become ineffective? Think about future filling challenges. ¿

continued

Nine tips forbuying liquid fillingequipment



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Best practices when implementingweigh/filling equipment

Weighing can be the most important operation in food processing, and the one with the

highest ROI within your plant. While almost any filling machine can potentially be set up to fill

by weight, weigh filling is more often used with dry products, such as powders or granules.

The challenge is determining the best solution for not only weighing, but also for handling

your product properly to minimize any degradation after the weigher. Confidence in boththe equipment and the supplier is vital when you consider the typical life of a weigher can be

more than 25 years. Here are some best practices:

1. Determine the overall system goals, looking at each transfer point. Carefully specifying each component of a system (like a weigher) is important, but all

components must work in concert to achieve the desired output, which is accurately filled

packages and efficiently running equipment.

2. Review your product’s flow characteristics with prospectivesuppliers. Send product samples for machine builders to test and ideally videotape. Thisis time-consuming and somewhat tricky if your product tends to change with transport and

handling, like produce. The trickier the product, the more important the validation.

Source: Weighpack



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3. Carefully examine and document your facility’s environmentalconditions. This includes humidity and temperature of the filling area, as well as bulkstorage. Depending on what is being filled, these conditions may have a damaging effect on

the product. They can even change the consistency of the product enough to have an adverse

effect on the equipment’s filling ability.

4. Make sure your sanitation practices and maintenance are top-notch.Avoid product buildup on tooling and control services. Choose equipment that is easy to

disassemble and clean on a daily basis or as required. Follow a rigorous maintenance schedule

to ensure top production output.

5. Consider how weighing/filling is affected by fresh, frozen, dry, fragileproduct. Weighing is affected by all product conditions, both physical and environmental.

The same product will convey, transfer, fall, and handle in a completely different manner

when fresh as compared to when it is frozen. The supplier should also have a large selection

of application-specific weighers to choose from, such as:

• Gentle-slope weighers for fragile products.

• USDA Dairy-approved systems if applicable.

• Weighers for fresh, sticky, and large-piece products, such as poultry.

continued

Best practices whenimplementing weigh/ filling equipment



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continued

Best practices when implementingweigh/filling equipment

• Weighers designed for RTE (ready to eat) freshproducts, such as salad kits, etc., which are extremely

popular right now but are challenging because they

may change in shipment, and are hard to validate.

6. Consider the unique challenges ofgranulars and particulates. Your supplier shouldhave a range of weigher models to handle different target

weights of granular and powder products. Consider

specifying sift-proof hoppers for your weigher, as well as a

dust collector for products that create high concentrations

of airborne particulates. You might also want some sort

of secondary automatic bulk loading of product to theequipment so that the machine is never under- or over-

filled with product. ¿

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Key implications of FSMA forfood packaging suppliers

On Jan. 4, 2011, President Barack Obama signed into law historic food safety legislation— the

FDA Food Safety Modernization Act (FSMA). The law has two major themes: prevention and

accountability. Prevention means that food companies need to have controls in place during

manufacturing to assure the safety of their products and to prevent problems (not just react to

them after-the-fact). Accountability means that food companies are accountable to the Foodand Drug Administration (FDA) to help ensure that their suppliers are making safe ingredients.

Although the law primarily has significant implications for food manufacturers, importers, and

the fresh produce industry, it also affects the food packaging industry. Importantly, not all

provisions in FSMA apply to food packaging in the same way. Some provisions of the new law

make food packaging manufacturers accountable to FDA, while other provisions make food

packaging manufacturers accountable to their customers. In order to help keep everything

straight, I encourage you to think about a few key principles as you read on.

• First, who does the legal requirement apply to? Some requirements apply to “food”as defined in the Federal Food, Drug, and Cosmetic Act (FFDCA), and others apply to

“registered” food facilities.

• Second, where is your business in the supply chain? Are you acting as a seller or as animporter/buyer?

• Third, who cares about your activities? Is it FDA or your customers (or both)?

BY ELIZABETH BARR FAWELL



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There are two major provisions in FSMA that are particularly relevant to food packaging

manufacturers and their relationships with their food-industry customers: Preventive Controls

and the Foreign Supplier Verification Program. Third-party certification is a tool that may help

ease compliance for food packaging companies.

Preventive Controls

The Preventive Controls provision is found in Section 103 of FSMA (FFDCA Section 418). It

requires all registered food facilities to evaluate the hazards that could affect food manufactured,

processed, packed, or held by the facility and to identify and implement preventive controls tosignificantly minimize or prevent the occurrence of such hazards and provide assurances that the

food is not adulterated and does not contain any undeclared allergens.

As stated above, this requirement applies to all food facilities registered as required by Section

415 of the FFDCA. By regulation, FDA has exempted food packaging companies from the

registration requirement (it defined “food” to exclude “food contact substances”). This means

that these companies are exempt from the legal requirement to comply with the Preventive

Controls provision—meaning such companies are not accountable to the FDA. But in practice,they are still accountable to their customers.

Although food packaging manufacturers are exempt from the Preventive Controls provision,

in all likelihood their customers—food facilities that use packaging materials to package

foods—are subject to it. And it is important to understand that one of the preventive controls

that registered food facilities will need to have in place is a supplier verification program.

Because food manufacturers will be required by FSMA (and FDA) to verify that their suppliers

continued

Key implicationsof FSMA for foodpackaging suppliers

C G G Q OO



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are making safe packaging materials, they may very likely require their packaging suppliers to

have preventive controls in place so they can meet their legal obligations.

Remember two of our key principles from above: Where are you in the supply chain? Who

cares? In this case, if you are selling food packaging materials to food manufacturers, FDA will

not require you to have preventive controls. Nonetheless, because food manufacturers (your

customers) are accountable to FDA, you will be subject to your customers’ oversight. And your

customers may require you to comply with the Preventive Controls provision or otherwise

assure them that your packaging materials are safe.

The Foreign Supplier Verification Program

The second major provision in FSMA is called the Foreign Supplier Verification Program (FSVP)

(FSMA Section 301; FFDCA Section 805). This provision applies to all importers of “food,” and

requires importers to perform risk-based verification activities to ensure that the food they

import is produced in compliance with the Preventive Controls provision (if applicable) and is

not adulterated or does not contain any undeclared food allergens. There are two definitions

that are critical to understanding how this provision may affect your business:

• First, FSMA defines “importer” as “the United States owner or consignee of the articleof food at the time of entry of such article into the United States” or the U.S. “agent or

representative of a foreign owner or consignee of the article of food at the time

of entry.”

• Second, for purposes of this section, “food” includes food packaging materials.

continued


FSMA’s Preventive Controls and Foreign

Supplier Verification Program provisions

are of particular relevance to food

packaging suppliers.




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Therefore, if you are an importer, and you import food packaging materials, you will need

to have an FSVP. If this is confusing, let’s look at our principles again: Who does the legal

requirement apply to? Unlike the Preventive Controls provision, which applies to registered

facilities, the FSVP applies to all importers of food, whether they are registered or not. Under

the FFDCA, the term “food” includes food packaging materials.

Although FDA exempted food packaging materials from the definition of “food” for purposes

of facility registration, that exemption only is an exemption from registration—the basic

definition of food in the statute remains.

It is possible FDA may grant an exemption from the FSVP for importers of food packaging

materials in the regulations implementing the provision, as some members of the packaging

industry have requested of the agency. As of this writing, FDA has written a proposed rule

implementing the FSVP, but that proposed rule has not yet been published or made publicly

available. Once FDA releases the proposed rule, the agency must provide time for public

comment on its proposal. At that time, food packaging manufacturers can comment on

the proposed rule to FDA expressing their support for an exemption. Even if FDA does not

propose an exemption in the proposed rule, it is possible that FDA may grant an exemption inthe final rule. So stay tuned.

Third-party certification

Furthermore, there is a tool at your disposal that may help you comply with FDA’s

requirement that you have an FSVP and/or your customer’s requirement that you have

preventive controls in place. The tool is third-party certification.

continued





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continued


If you are an importer, you can use third-party certification

as a verification activity. That is, you can require your

suppliers to get certified. Then, meeting the FSVP

requirement is much easier. If you are a supplier, you can

use third-party certification to show your customers you

have rigorous programs in place to ensure safety and

quality. You can show your customers you are certified,

and then they can more easily satisfy their obligations

under FSMA. (Please keep in mind that you are not legally

required by FDA to use third-party certification. I am merely

suggesting it as a potential tool for your consideration.)

Conclusion

In the end, the passage of FSMA means that big changes

are coming for food companies everywhere, and that

applies to makers of food packaging as well. As you think

about preparing for compliance with the law, be sure you:


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ABB Robotics. The broadest portfolio of high speed picking

robots in the industry.

The new 6 kg and 8 kg IRB 360 FlexPickers handle higher payloads with greater working

depths, and are able to pick-and-place up to 500 products per minute. Along with the

1 kg and 3 kg FlexPickers, all variations are available in sanitary models, ideal for direct

food handling or pharmaceutical applications, including a hygienic design for wash down

applications and an IP69K rated stainless model. Learn more at www.abb.com/robotics

ABB Inc.

(248) 391-9000

www.abb.com/robotics

[email protected]

continued


Understand which provisions apply to registered food

facilities (Preventive Controls), and which apply to importers

of food (FSVP).

Think about what activities you need to engage in to

satisfy FDA (FSVP), and what you need to do to satisfy your

customers (preventive controls).

Work with others in your industry to see if FDA will grant

an exemption from the FSVP for food packaging materials,

and think about whether third-party certification makes

sense to satisfy both FDA (if applicable) and customer

requirements. ¿


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Auger filling equipment trendsand buying tips

What has most affected the design of auger filling equipment in the last year or two? It boils

down to these trends:

1. Greater throughput and reliability with servos: For more than a decade, servo-

motor technology has increasingly found its way into dry filling lines to become a mainstreamtechnology for all package sizes—from club packs to stick packs, K-Cups, and single-serve packs.

This technology allows precise control of acceleration rates and revolutions for greater accuracy

and repeatability as well as reduced product giveaway. Along with the accuracy of turning on

and off “cleanly” with every fill, servos also can automatically shut down in the event of a line

stoppage, eliminating the burnout of old AC motor and clutch-brake designs. Also in contrast

to older AC systems, servos use fewer parts for reduced maintenance. These benefits, taken as a

whole, have allowed greater management of complex lines and greater confidence to expand,

for instance, a K-Cup filling line from two to eight or more lanes.

2. Quicker changeover: Along with greater control and reliability of dry filling lines,machine design enhancements open new opportunities for making incremental gains in capacity,

especially in the area of changeover. For example, when reconfiguring the appropriate number

of filling heads for a change in package or product, new designs offer easy access to parts,

speeding cleaning and changeover. This can be seen in the reduced tools, and in some cases




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tool-less changeover procedures, that contribute to greater productivity for greater throughput,

while at the same time reducing the risks of unnecessary tools and “loose” parts in the production

environment.

3. More powerful controls: The wide adoption of programmable controls has led tomore powerful management and integration of filling equipment. Current-generation dry filling

equipment is typically integrated with upstream infeed systems and downstream baggers, such

as horizontal or vertical form/fill/seal systems. Additionally, checkweighers further downstream

communicate with that equipment to automatically adjust feed and fill settings and prevent drift

in weight and other parameters. The advent and adoption of control and software standardshave led to more cost-effective, plug-and-play compatibility for great reductions from software

programming to hardware costs that range from wiring and maintenance to spare-parts stores.

4. Increased sanitation: Particularly in the food industry, packagers are looking atsanitation levels more closely than ever before. New laws such as the Food Safety Modernization

Act in the U.S. have prompted the design of machines that are more sanitary and easier to clean,

reducing or eliminating cracks or crevices that can capture food particles, and streamlining

extraneous machine parts that might inhibit cleaning. Suppliers are also upgrading from 304stainless steel to 316 stainless steel, for the additional resistance to corrosion and staining the

higher grade delivers.

continued

Auger fillingequipment trendsand buying tips




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continued


Buying advice

When it comes to purchasing auger filling equipment, it’s critical

to make the equipment manufacturer aware of your container or

package design as early in the process as possible. A manufacturer

may be able to give input into package design that will positively

impact line speed. For example, if your container opening is too

narrow, increasing it by ¼ of an inch may greatly increase filling

speeds, as well as provide benefits to the consumer regarding

ease of evacuation of the product.

To select the right equipment for your application, the

filler manufacturer will need to know the target weightand the speed requirements in packages per minute.

Accuracy requirements should also be known. These three

factors—weight, speed, and accuracy—are not always

simultaneously achievable. You might need to give up one

to get the other.


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REA JETREA REAL DEMANDS. L SOLUTIONS.www.reajetus.com

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Laser Marking Systems

Your global leader incoding & marking systems

continued


Of course, this means that the product you will put in

your container is just as important as the container itself.

Products that are free-flowing like salt or sugar are handled

differently from those that are lumpy or prone to bridging.

Density is another factor to measure, and if you don’t know

it, the machine manufacturer should have the resources and

capabilities to account for it.

A holistic consideration of package, product, and machine

characteristics can speed machine design, testing, and

successful implementation of your dry filling line. ¿


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Nine best practices forselecting capping equipment

There are few key things to keep in mind when buying and specifying capping machinery:

1. Know your closure. The tip we heard the most, from both suppliers and end users,was that you must understand the tolerance of the closure itself and then marry the material

tolerance to the machine tolerance. You must completely understand all the geometry,tolerances, and measurements of your closures before you order a machine. For example:

What sort of pressure does a snap-on closure take? With a screw-top closure, you might

be able to use 20 times more force, but how many times do you have to rotate it? Often,

packagers don’t take into account the type of closure and balance the application torque and

removal torque required by the consumer. Induction sealers add another variable, as they

may loosen caps, requiring the addition of a retorquer. Additionally, every closure has a decay

time on the removal torque; you need to know the decay time, because it may loosen on the

shelf. Know this information and share it with your supplier.

2. Consider both the consumer and the machine. Because the cap hasto interface with both. Consider the size of the bottle opening from both a filling and

evacuation standpoint. Also evaluate whether to use a single-closure assembly versus a

two- or three-piece cap assembly. The geometry of the package must be considered first,

and then you should explore the type of feeding system you need to deliver the closures to

the capping machine.




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3. How will the closure design interface with the machine function? Before you consider centrifugal sorting bowls, you must know the height and diameter of the

part versus the length of the part, as well as the weight bias, to determine if it will sort well, or

at all. Other considerations include: Do the sidewalls have paper or not? This makes it more

unstable in handling. You must look at this in a very granular fashion; you must know what

the natural tendency of a part is before you toss it into a sorting bowl. It’s critical to know

how the cap design will interface with the machine function. And you have to know that

before you apply any sort of force to it. You have to find a way to differentiate shapes in the

sorting bowl. Once you know the natural tendencies of a part, you can assist those tendencies

through the design of your machinery, and you will achieve more reliable operation whencapping and handling. One philosophy is to permit machine function to drive closure

design—in other words, make sure that the design of the cap is compatible with what’s

typically available in the way of unscrambling and orientation equipment.

4. Consider future closure flexibility. Like any other packaging machine, try toanticipate future needs. Capping machines may need to be able to deal with a variety of

different types of closures over time. Over the years, cap designs and applications have

become increasingly complex: For example, spray-through caps must be oriented with thegraphics on the container.

5. Rotary capper considerations. When looking at rotary machines, examine thenumber of heads and infeed method (starwheels or screws). A key element to look at is how

the cap is applied. Servo-driven chuck applications permit easy changeover to different

closure styles. Closure pickup is critical, as is chuck handling. Look at the capper’s centering

mechanism and any anti-rotation devices to ensure proper closure placement.

continued

Nine best practicesfor selecting cappingequipment




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6. The need for speed. Think about how many heads are required to achieve yourcurrent line speed, and make sure you have the ability to add heads later for higher-speed

applications.

7. Examine container handling and stabilizing. For some lighter-weight plasticbottles, you’ll need to look at the machine to assess how well it holds the container tightly in

place during the capping application and torquing to assure a good seal, especially for food

products.

8. Test tolerance variances. Look at what your container and closure suppliers areproviding in terms of both the widest and narrowest tolerances. Test the opposite extremeswith one another and see how the machine handles it. You’ll obtain valuable insight into how

flexible the machine will be with borderline materials.

9. Test known bad inputs. Deliberately feed in the wrong container and thewrong closure. This is known as induced failure testing. This is part of trying to simulate

what happens on the third shift, when operators may be tired and not as aware of their

surroundings. What happens if material is loaded in the wrong way? If operators load thewrong caps? Will that break the capping machinery? Better to find out before you buy. ¿

continued

Nine best practicesfor selecting cappingequipment




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In-line cappers versus rotarychuck-style cappers

In-line cappers are traditionally cheaper than rotary chuck cappers, which can cost up to 10

times the price. In-line cappers will typically have a smaller footprint than a rotary machine. In

many cases, an in-line machine can be mounted over an existing section of bottle conveyor.

Finally, in-line cappers typically have lower costs for the additional change parts required to

run different sizes of containers and closures.

Rotary chuck cappers have much higher speed capabilities than in-line machines. Chuck

cappers can be supplied with as many as 40 heads that operate at production speeds from

as low as 10 bottles/min to speeds as high as 1,200 bottles/min. (In-line cappers are typically

speed-limited to a maximum of 200 bottles/min. In-line cappers are limited in the diameter

of cap that can be dependably applied—typically 28 mm to 70 mm. An In-line capper will

generally be limited to applying closures that are round in shape. Chuck-style cappers can

apply round, rectangular, square, oval, tapered, and reverse-tapered caps.




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Inline Series 5100

We’ve simplified your game plan.Our line of pressure-sensitive labelers are designed tomake labeling easier. The Inline 5100 Wrap LabelingSystem automatically spaces your products and featuresconvenient tool-less wrap station adjustments. Gettingset up should be the least of your worries.

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continued

In-line cappers versus rotary chuck-style cappers

Chuck-style cappers have an advantage over in-line

machines when applying closures with tamper-evident (TE)

bands. The TE band typically has an interference fit with the

threads on the neck finish of the bottle. Direct pick-off of

these caps by the bottle results in the caps sitting crooked

on the bottle finish and generates a high number of cocked

caps with in-line machines. A chuck-style capper has a TE

cap positively held by the jaws of the chuck, and the TE

cap is brought down squarely onto the bottle finish and

held securely during its entire application, avoiding the

incidence of cocked caps. In addition, the capping head on

a chuck-style machine can deliver a downward force (top

load) onto the closure as it is being applied. Top load helps

force the TE band over the thread finish of the bottle neck

to properly engage the threads of the cap with the threads

of the neck finish. ¿

This article was adapted from a Fowler Products Co. white paper.


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Trends in coding/marking forprimary packaging

A number of trends are shaping the development of coding and marking equipment for

primary packaging:

1. Better integration capabilities. While equipment controls have remained

relatively the same, machines have evolved to integrate more effectively across thepackaging production enterprise, particularly to ensure that coding on the case ties into

the package itself.

2. Triumph of the visual. Not only has packaging become more graphic (see point 4,next page), but coding equipment has also. Coding suppliers are incorporating better and more

colorful touchscreens to help simplify operation, improve productivity, and maximize control.

Even ink containers have become more visual: In many cases, bottles have given way to self-

contained cartridges that have meters for easy and more accurate visual assessment of levels.

3. Designed for traceability. Regulatory pressures at multiple levels continue toincrease the need for products to be traceable throughout the distribution chain. The food

industry has taken the lead in this effort with the adoption of the Produce Traceability

Initiative; it includes an action plan to achieve whole-chain electronic traceability by the end

of 2012. Other industries, most notably pharmaceuticals and CPG, are likely to follow suit in

the near term.

BY MARTY WEIL

Source: Domino


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C G G U OO


continued

Trends in coding/marking forprimary packaging

4. Customer-driven standards. The requirementsthat coding and marking equipment must meet are being

driven less by manufacturers than by the customers of

manufacturers, such as Walmart, Target, and Costco. The

way manufacturers are implementing coding and marking

equipment depends on their customer mix.

5. Response to harsh environments. In harshenvironments, there is greater variance in stainless steel

on bagger machines, but in environments with caustic

chemicals, stringent stainless grading is the rule. Also,

better bracketry is being used, along with print rollers that

are food-grade acceptable. ¿


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36 / 127EQUIPMENT STRATEGIES

Ten tips for buying coding/ marking systems for primarypackaging

Even for packaging veterans, coding and marking can be tricky. The equipment is high-tech

and high maintenance. It requires an extra dose of operator training, advanced cleaning

techniques, and the willingness to periodically update capabilities and analyze theireffectiveness. The following practices are recommended to those specifying new or upgraded

coding and marking equipment for primary packaging:

1. Know your operation. Careful analysis can make the difference between a successfulcoding installation and one that experiences needless downtime, resulting in unhappy

customers. Once you know these factors, it will be easier to choose which marking and coding

technology is best for your application. Key factors to consider include:

• Types of materials or substrates you’ll be marking

• Desired speed of application or throughput

• Print quality: permanence and readability

• Up-front investment your company is willing to make

Source: Domino




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D-Series Laser Coders

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The new i-Tech scan head is beautifullycompact and ts where larger ones cannot.

The multi-position head makes it mucheasier to adapt to your production line

from any angle, even in the most restrictedof spaces.

Modular construction includes an optionof standard or IP65 casings, and makes theD-Series laser’s footprint smaller overall.

Altogether a more compact industrial design(and 20% lighter) the new, smaller D-Series

is a big improvement all round.

Domino. Do more.www.domino-na.com

1.800.486.7414

continued

Ten tips for buying coding/markingsystems for primary packaging

• Whether variable data, graphics, and bar codes areneeded

• The distribution cycle characteristics for your packaging

2. Find room on the package, and room onthe line. Make certain an area of “real estate” on thepackage is available and accessible to coding and marking

equipment during the packaging process. To accomplish

this, make sure your packaging line OEM works with

your coding supplier early on to ensure all the necessary

requirements for integrating the marking and coding

equipment are considered. Too often, marking and codingis an afterthought in the line layout, and packagers find

themselves scrambling to find an area on the package to

mark the variable information, like date and lot number,

and an accessible area of the packaging line to accept the

marking and coding equipment.


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3. Know your coding options. Ink-jet doesn’t work for logos on a primary package.Some types of ink-jet technologies don’t do bar codes well; use thermal transfer instead

for bar-code applications. Specify to the vendor the grade, printing substrate, and printing

application. Fully understanding the application will reduce costs and increase coding

efficiency. On-demand or preprinted labels? Preprinted labels work for operations that have

a volume of identical labels with many colors or complex graphics, because this option saves

both time and money. However, to be flexible and responsive to operational changes, on-

demand labels can provide a solution for those with variable data.

Ink-jet, laser, or thermal printing? Ink jet works well for printing cartons and productpackaging, but is not necessarily ideal for all bar-coding applications. Laser printing works

for some bar-code applications, but requires an area to be printed on the label (assuming a

white label) that can be “burned” off to leave the variable information

behind. Its higher up-front costs (compared to ink jet) are offset by

the fact that laser printers run longer without issues, are cleaner, and

have almost no moving parts. Direct thermal is a simple process that

works well with printed labels that have a short shelf life and are not

exposed to heat, sunlight, or rough handling. Thermal transfer canhandle heat and moisture as well as the vagaries of shipping and

the distribution environment. When looking at the options, don’t

just consider cost of hardware—think about costs of supplies and

consumables as well. If you are presenting a prospective supplier

with a challenging application, an online demo of the equipment

you are considering is always a wise choice and in most cases will

make your decision much easier.

continued

Ten tips for buyingcoding/markingsystems for primarypackaging

Primary packaging—plan to add or switch to these coding methods

Source: Packaging World Reader Survey January 2013

Other (please specify)

Continuous ink-jet (CIJ)

Thermal ink-jet (TIJ)

Laser

Thermal transferoverprinter (TTO)

Print-and-apply labelers

34%

14%

31%

15%

19%

17%




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4. Value versatility. How versatile is the coding system? Are you choosing a flexiblesolution that enables quick response to new packaging substrates or configurations? Brand

owners understand that new and “fresh” packaging has a direct and positive impact on sales.

New packaging configurations are changing faster than ever. Can your coding system adapt?

5. Realize that no machine is an island. Can the coding system you’re consideringbe integrated for improved efficiency? Historically, coding and marking printers have been

purchased and installed as stand-alone devices. Today, automation and integration is increasingly

important for improving efficiencies and as a means of reducing errors. For example, packagers are

networking coding equipment in their plants, both horizontally and vertically. In other words, theyare creating a central command post that manages information not only among production lines,

but also among primary, secondary, and tertiary coding systems. The ability to enter a product

code one time and have it quickly download from product to pallet printing stations can save

significant time and reduce message entry errors. There are solutions available today that offer a

coding automation platform that provides a modular approach, allowing entry-level investment

that can grow into fully automated integrated systems.

6. Find a coding partner. Consider investing some time up front to find a codingand marking partner and simplify your life. Most plants have multiple brands of printers.

This makes managing your printer fleet and coding supplier relationships complex. Large

suppliers that can install and service one brand of printers that serves all coding needs (up

and down the production line) can make your life easier with coding user interfaces, technical

training, and service programs—not to mention one phone number to call for your coding

requirements. Obviously this increases sales for the big vendors, but it provides cost and time

benefits for packagers as well.

continued





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7. Know the operating costs. While initial cost is a significant factor, the cost ofownership has the most impact on budgets over time, as well as effect on the supply chain

relative to production. You need to know operating costs: energy, materials, maintenance,

repairs, parts replacement, and service. Make sure you understand the impact of all costs

before proceeding with a particular supplier.

8. Prepare for future legislation. The Food Safety Modernization Act (FSMA) willimpose new requirements for machines used in food packaging. You should expect, and

require, your machinery vendors to help you meet those requirements. Understanding how

your coding supplier is preparing and positioned to meet these requirements can reveal a lotabout their seriousness about building long-term partners versus short-term sales.

9. Invest in training. The real barrier to effective coding is knowledge. Make sure all yourmaintenance personnel have knowledge of the equipment—not just one or two people on

each shift. See that the vendor-trained personnel, those with really detailed knowledge of the

equipment, spread that knowledge to all maintenance and production people on every shift.

This investment will pay off in reduced downtime.

10. Take the precautions equipment demands. When dealing with lasers, productmust be well-guarded and people must be protected. You must have a fume-extraction process

in place, so whatever you’re burning off doesn’t stay in the environment. With ink-jet printers,

consider self-cleaning options to eliminate problems associated with clogging. System design

should be hygienic, preventing foreign materials from adulterating the ink. ¿

continued


Download

Survey

Packaging World magazine recentlysurveyed coding end users about their

current and possible future usageof coding technologies.

To see the full survey, click here.

http://bit.ly/Coding_Survey

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Comparing coding technologies

Continuous Ink Jet (CIJ) and Thermal Ink Jet (TIJ) are the two predominant ink-jet

technologies used in primary package industrial coding applications. Laser systems, which

have experienced steady increases in adoption over the past 10 years, are offering a third

option in industrial coding applications. Thermal Transfer Overprinting ( TTO) has found

increasing application with flexible packaging. Each technology has an inherent set of

operating considerations. When choosing among them, it is useful to consider the strengths

of each technology.

CIJ strengths:

• It adheres to most packaging materials and can be used on curved surfaces, such as thebottom of a soda can.

• It is capable of achieving very high speeds for alphanumeric codes.

• Many small-character CIJ printers are portable and can be moved from line to line asneeds arise.

• The latest generation has significantly improved reliability with decreased maintenancerequirements.

Source: Videojet

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• Small-character CIJ printers create lot codes, expiration dates, bar codes, and graphics

on a wide variety of primary packaging, while large-character CIJ printers do the samefor secondary packaging, such as cartons and corrugated boxes.

TIJ strengths:

• Works well on porous and semi-porous materials (e.g., chipboard cartons with anuncoated printing area). The high resolution (typically 300 dpi or above) makes it an

excellent choice when visual appearance of a bar code is important or when used with

a camera-based code verification system.

• Maintenance is simplified because the print head and ink are contained in a low-cost, disposable cartridge. In the last few years, significant improvements to ink-jet

printers make them cleaner and easier to use, regardless of which technology is being

employed.

• TIJ printers enable high-speed coding of serialized data and many types of bar codes,including GS1 DataMatrix, to be compatible with track-and-trace applications.

• Advancements in print-head technology include automated cleaning and a perforateddesign that reduces ink and debris build-up across the face of the print head.

continued

Comparing codingtechnologies

Source: Videojet

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• TIJ printers are inherently clean and easy to use due to their replaceable cartridge

design. As inks become available that are darker and deliver better dry times, andprinter vendors offer more rugged industrial designs, TIJ technology is experiencing

increased adoption.

Laser strengths:

• While requiring a higher initial investment, lasers offer high reliability with minimalmaintenance and good print quality. These factors will continue to drive an increased

usage of lasers in industrial coding applications.

• It can be used for marking numerical codes, 2D-matrix and bar codes, logos, andsymbols onto labels, sleeves, glass and plastic bottles, cans, kegs, tubes, blisters,

cardboards, tubular films, and caps.

• The advantages of laser coding include speed, versatility, code permanence,noncontact operation, clean and dry process, maintenance-free operation over

thousands of hours, extremely low operating costs, and adaptability to a fully

automated line.

• Lasers also offer high reliability in “no-code/ no-run” operations. This means that if it’smandatory to code the product prior to distribution, then production will stop if a

product is coded incorrectly.

continued


Source: Videojet

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Laser coding vendors are often asked about the difference between laser ablation and laser

color change. In most cases, the substrate will determine if you need to choose between laser

ablation and color change. Most of the applications of a CO2 laser are laser ablation, where

the top color is removed, and the color underneath shows through. There are some limited

substrates that actually change color when marked with a CO2 laser, with polyvinyl chloride

being the most common. CO2 lasers are often “engraving” what they mark, which can slightly

alter the color, as seen with PET bottles. When marking PET bottles with a CO2 laser, the mark

turns slightly opaque, which allows it to stand out more. That is, the color does not change,

but the material reacts to the laser to cause this effect. YAG lasers perform a color change on

most plastics, which is caused by the effect of the 1064-nm wavelength of the YAG laser on

the material to be marked. The best way to determine the optimum laser technology for your

application is to provide samples to your sales representative, who will advise you of your

options.

TTO strengths:

• TTO features a thermal transfer print head and ribbon that makes contact with a flexiblesubstrate, such as synthetic films and plastic labels. Miniature print elements under aglass coating heat small areas of the ribbon and transfer ink to the target substrate.

• Print elements are program-controlled to create real-time images, including clean,high-resolution bar codes, text, and graphics.

• TTO systems can address applications in both continuous (moving) and intermittent(stop-print-start) environments.

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Q M N S A G S

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continued


Primary Packaging - Coding Options

ContinuousInk Jet

Laser ThermalInk Jet

Thermal TransferOverprinter

Comments

Folding Carton 2 1 2 3 Conduct laser sample testing

Metal Can 1 3 3 3 CIJ most optimal for this substrate

Shrink Wrap 2 3 2 3 Consider TIJ and conduct sample testing

HDPE Container/Pouch

1 2 2 2 CIJ likely best option (for strong TCO and substrateadhesion), but if laser or TIJ work, this could be a goodalternative

PET Container/Pouch

2 1 2 3 Laser is typically an excellent option

Glass Container 1 2 3 3 CIJ and laser used extensively for glass printing

OPP Container/Pouch

1 2 1 2 Generally a difficult substrate to mark

CPP Container/

Pouch

1 2 2 1

BOP Container/Pouch

1 2 2 3 Often limited to CIJ coding

Paper Container/Pouch

1 2 1 2 TIJ may be an excellent option

Coated Foil Pouch 1 1 1 1 Generally there are many coding options for this substrate

Foil Pouch 1 1 2 1

It is recommended to conduct sample testing for allapplications and substrates

1 - Best fit 2 - Good fit 3 - Not a good fit

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Delivering speed and performance

to keep you way ahead of the curve.

The of pharma packaging H E

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Uhlmann Packaging Systems LP

44 Indian Lane East

Towaco, NJ 07082-1032

973-402-8855

www.uhlmannpackaging.com

[email protected]

• Double-lane, integrated blister and carton module• Easy to operate with minimal downtime and

automatic changeovers

• Handles up to 500 blisters/cartons per minute

• Ideal footprint, less than 10 meters long

• Efciency guarantee (call for details)

Introducing theultra-efficient Uhlmann Blister Express Center 500

Uhlmann Blister Express Center 500

continued

Comparing coding technologies

• Typical applications for TTO are within the snack,bakery, meats, and frozen food industries, where

flexible packaging is common. Such packaging also

plays a big part in the retail hardware sector, where

items like screws, nails, and fittings for do-it-yourself

projects are sold prepacked.

Ultimately, when deciding on a coding technology, the

strengths of each must be matched with how well it will

integrate with other equipment on the line. It is critical to

match the production line communications with printer

capabilities, as well as ensure that the printer has the

ability to process the information and print at the speeds

necessary to meet production demands. ¿

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Best practices for specifyingconveying and containerhandling equipment

Despite their importance, conveyors and container handling technologies are often an

afterthought. They shouldn’t be. Things to consider:

1. Buy the conveyor pre-integrated. When considering a new line, it’s oftensmart to buy the conveyor as part of the machine. If you’re buying a packaging machine

as a replacement, it might be tempting to retain the old conveyors, but be aware that the

match might not be optimal, especially at transfer points. If the machinery builder supplies

the conveyor already integrated, it reduces installation costs (versus purchasing a separate

conveyor), installation time, and line commissioning of I/O devices. This will also ensure that

no stand-alone control cabinet is required and that all variable frequency drives (VFDs) and

devices, and the power panel and PLC control panel are assembled onto the conveyor legsand frame. All the information will show up on one screen—motors, alarms, and controllers—

making things simpler for the operator, technicians, and engineering staff.

2. Understand how your containers behave. You need to consider packagegeometry, center of gravity, and mass when specifying conveyors. For example, empty

PET bottles act differently under pressure compared to filled bottles; hence the conveying

and container handling has different requirements on different stages of the line. Fully

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