MACHINE BUILDING, FRAMEWORKS & SAFETY FEATURE
In response to requirements to ensure packaging waste is fully recyclable by 2025, Klebo Techniek has worked in collaboration with Lenze to develop a machine capable of producing 120 BeeMagicTray’s per minute for packaging supplier Dampack
A FRESH IDEA FOR PACKAGING PRODUCTION P
ackaging waste is a huge problem across the world, however companies are now
developing solutions to ensure that, by 2025, all packaging waste is fully recyclable. One example is the BeeMagicTray which has been developed and patented by packaging supplier
freedom and it makes it easy for us to deliver in a customer-specific way. We encounter quite a few different wishes from our customers and wanted to be able to respond quickly. When we came into contact with Lenze it soon became clear that we could not only put our wishes in their hands, but also work with the same philosophy.” Modularisation is
a common approach at Lenze, according to
Spekreijse. “We saw similarities in all areas. Not only in the
Dampack. Designed for use on supermarket shelves, the bottom of the plastic tray has a special honeycomb structure that ensures less loss of moisture from food and a better shelf life. The entire tray, however, is manufactured in one material, enabling easy recycling. The tray is manufactured on a machine
developed by machine builder Klebo Techniek from Holten, Netherlands, and features technology from Lenze which is not only helping to maximise output but also the OEE, flexibility and safety of the machine.
modular approach to controllers, but you see that Lenze is a family business and that atmosphere also suits our company. You really feel that they are committed to you and your project. We were really impressed by their approach, both on the communication and technical side.” To meet the requirement for 120 trays per
minute, all parts of the process were examined – from the input of the material to the output of the finished product. Leetink added: “Thanks to the dimensioning software from Lenze we came to the conclusion that certain movements could be better done differently. Every aspect of the line was therefore completely recalculated.” While the modular design of the drive
technology and process control allowed the machine to be controlled at a detailed level, real value goes beyond that, as Spekreijse explained. “We will soon have a lot of detailed information available to us for the service, without needing the product information or recipes. This will enable us to monitor the status of the various components very well.” In the process itself, the modular structure
MEETING REQUIREMENTS Originally the machine had the ability to output between 80 and 90 pieces per minute, however the company wanted this to increase to 120. The system also had to be supported worldwide, so Klebo wouldn’t have to be dependent on a system integrator, by using standardisation and also data for OEE and predictive maintenance. Commenting on the cooperation between
Klebo and Lenze, Johan Klein Leetink and Rob Spekreijse, said: “We wanted to remain the owner of the solution. Our programmer indicated that it would be best to build the control of the machine at block level. That gives much more design
and division of the process steps have helped. “The positioning of the sealing sheet was not yet properly controlled, but the servo technology from Lenze has made a real difference. We use several servomotors and, with a little trick, we were not only able to position the sheet very precisely but also to increase the speed of positioning enormously,” Spekreijse added.
/ DESIGNSOLUTIONS
COOPERATION The different steps in the machine are: de-stacking the trays, feeding them into the glue stick machine, inserting the sheet, welding and checking the stacking. Following this, operations such as pick & place, film unwinding, temperature control of the seal, the drive of the web, and the synchronisation of all movements come into play. Spekreijse said: “We have set up the individual
actions as separate software function blocks and these make the layout of the machine very flexible. But the interaction of all that has to be calculated very accurately in order to achieve an optimal alignment of the position controls. All processes are perfectly in line with what we want and the cooperation is great. The next two projects with Lenze are now also underway. “For us, the added value of the cooperation
with Lenze lies in several aspects. Lenze has a good after-sales service, production in all parts of the world, many standardised, easy to program controls, and a lot of data to read out. That helps us to further increase OEE – among other things by predictive maintenance, and data from the various functional parts of the machine. We can immediately see at which points deviations occur and, in combination with the information about the drive systems, we have our finger on the pulse. In this way, we can also see where there is still room for improvement. With the supply information, quality data, rejects, measurements and data from the process flow, but also from the I/O modules and the sensors, you have an incredible amount of information at your disposal and you can analyse every aspect down to the smallest detail. Thanks to remote access, visualisation and the connection with the cloud, you can learn about the machine’s lifecycle and its influence on OEE.”
Lenze
www.lenze.com/en-gb
The tray is manufactured on a machine developed by Klebo Techniek and features technology from Lenze
DESIGN SOLUTIONS | APRIL 2021 13
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