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ADVERTISEMENT FEATURE COVER STORY


Hepco V guide systems: the bread and butter for food applications


Hepco’s DTS2 Driven Track System has been developed for high-speed and dynamic applications. O


ne of the largest industries globally, the food and beverage industry is a


core element of the UK manufacturing economy. Comprising of many different sectors including the bakery sector, confectionary, meat processing, drinks industries, dairies and fish processing – the range is wide and demand is high. The fundamental element of any food


manufacturing application is how to guide and transfer the components around the system. Whether it’s carton forming, pre-feeding, pick & place, or filling, the components need to move between processes, and it is the guidance system that provides the necessary linear or circular movement for this. The standard choice for many designers based on purchase price alone is likely to be ball rails, and in many situations, this type of system will meet the demand of the application. However, the packaging industry is notoriously demanding and highly competitive, with high speeds, short travel strokes and high throughput. In this type of environment, with the hourly downtime costs to consider and the required system life, alternatives such as Hepco’s V guide systems can offer a cost saving over the total cost of ownership of the system.


V GUIDE SYSTEM Hepco’s V guide system was conceived to meet the challenges faced by packaging manufacturers; low maintenance, ease of installation together with solutions that can perform in any environment. Marking its 50th anniversary this year, Hepco has extensive experience providing a range of high speed and accurate solutions for


the food industry. Hepco’s V guide technology functions on the basis of tight geometrical control over matching slide and bearing V’s. In turn this provides a wiping action in operation with the speed of the bearing at its circumference being faster than the speed at the root diameter of the V. The resulting action causes dirt to be pushed to the extremities of the bearing, allowing dirt and debris to be wiped away. Components that can reduce the ingress of dirt will be quicker and easier to clean, allowing quicker cleaning cycles and therefore less downtime. With many food applications working 24/7


and processes becoming ever more automated, the need for equipment and machinery to be reliable and efficient is vital to production. One key way to maximise production and increase profit is to minimize downtime.


MINIMIZING DOWNTIME Downtime is one of the biggest challenges in food manufacturing due to the cost implications associated with it. Every minute a machine is not up and running equates to lost time that could be spent creating a product that contributes to profit. Food packaging applications need to stay on schedule and produce high product throughput with utmost reliability in order to be profitable. Downtime is costly whether it is planned or


Hepco’s V guide system has a unique wiping action that expels debris


unplanned. Downtime per hour, per system differs dramatically between industries and specific manufacturers. Customers within the food packaging industry have downtime costs varying from £500 - £100,000 per hour, highlighting how longer downtimes can really impact on businesses. Minimizing downtime is a key driver for many customers and Hepco’s V guide system offers a real advantage by reducing maintenance time with features such as minimal re-lubrication intervals, the


16 APRIL 2019 | DESIGN SOLUTIONS


ability to eccentrically adjust bearings and offering a longer system life.


LUBRICATION Due to the high speed, high throughput requirements in the food industry, lubrication is essential to minimize friction and wear, dissipate heat, prevent corrosion and ultimately to extend the system life. Ball rails rely on consistent, effective lubrication in order to reduce wear of the recirculating balls and associated rails. Re-lubrication intervals are far shorter for ball rails than Hepco’s V guide systems, with frequent maintenance and downtime required to keep them running. Re-lubrication intervals for ball rails will vary depending on the condition but manufacturers state clear distances for re- greasing often as low as 50km. Re-lubrication intervals are far longer for V guide systems and less lubricant is required to work effectively, saving valuable downtime and cost. It is not unusual for intervals of up to 1000km of travel before having to apply additional lubrication to the bearing cap seal. Systems that can deliver continuous operation, without the need to be regularly stopped for routine maintenance such as re-lubrication, are highly valued by designers and production engineers alike. V guide systems can also use an automatic


lubrication system which delivers lubricant directly to the contact surface between the slide and the V bearings. Customers such as Bosch Packaging Technology use this in their award- winning Kliklok Integrated Topload Cartoner (ITC) system. Offering the highest speeds available for a solution with such a small footprint, the system operates at 2.5m/s and up to 80 cartons per minute are formed, loaded and closed on the ITC. High product throughput is a key requirement, therefore low maintenance is a must. The system uses a 6m long GFX Guidance System for Beckhoff XTS eXtended Transport


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