UNIT FIVE
PACKAGING MACHINERY
第五单元 包装机械
Lesson 18
General Overview
第 18课 概述
Automated Production
Today,automated production is essential,Neither
volume nor product consistency can be achieved in any
other way,Increasing production in a cost-effective
manner is a difficult and complex undertaking,The
project engineer overseeing such a project must have
strong support from management,production,
maintenance,and vendors,Delays,errors,and higher
costs will result if this support is not totally integrated,
with all concerned playing an active role,
Automated Production
Increasing Production
Four options to increase production are,
Buy new state-of-the-art equipment,
Do something with existing equipment,
Buy refurbished equipment,
Hire a contract packager,
Factors that will influence this choice are as follows,
Availability of in-plant equipment
Market demand for the product
Automated Production
The time frame in which the product must be produced
Production volume
Quality standards
Equipment technology
Space constraint
Installation requirement
The New Production Line
The Packaging Machine Industry
Packaging machinery manufacture is a highly
specialized business that does not produce large
numbers of identical machines,
Products and packages come in such an
infinite variety of materials and forms that even
though a company may specialize in a particular
machine class,In this respect,packaging
machinery is a custom business,
The New Production Line
Given that a complete packaging line may consist of
six functional stations from six suppliers,connected by
conveyors and buffers made by still another supplier,it is
not likely that a new line can be plugged in and work
instantly and perfectly,New lines have to be debugged
and brought up to operating speed,Good production
engineers can usually coax a bit more speed out of a line
given time and experience with the process,
The New Production Line
General Considerations
Broad decisions as to machine class need to be made
early and are usually obvious,For example,
Will it be a dedicated machine or will it need
interchangeable parts?
Are particular standards of cleanliness and sterility
necessary?
Are active chemicals needing special corrosion
protection procedures a factor?
Should the machine flow be from left to right or right
to left?
The New Production Line
When examining candidate machines,remember that
good packaging lines accomplish their objective with a
minimum of vibration and noise,
The transfer and flow of product and material through
the production process should be smooth,with the
minimum of directional changes,
Before calling on machine suppliers,make a thorough
and critical analysis of what exactly needs to be
accomplished,
The New Production Line
Be realistic in the range of tasks that your machine will
be required to perform,and resist the temptation to
compromise the main objective,The more dedicated a
machine is,the more efficient it will be,
Capital outlay for machines can be heavy,
Effective servicing and parts supply is a key vendor
issue,
Speed
Terminology
The lack of specific and consistent terminology often
makes discussions of productivity confusing,For the
purpose of this discussion,the following definitions will
be used,
Packaging line,A group of integrated special-purpose
machines that combine product and package inputs and
produce a new product,The individual machines,each
performing a different function,are referred to as stations,
Input,Specific product and package items required for
package assembly,
Speed
Design speed,The theoretical capacity under perfect
running conditions,The speed of the machine as
designed,running empty,is the design cycle rate,
Capacity,The upper sustainable limit of quality
packages passing a point just before warehousing,
Run speed,The instantaneous operating rate at a point
in time,
Output,A packaging line’s output (designated Y) is the
exact quantity of quality product passing a point just
before warehousing or shipping in a given time,A
machine’s or station’s output is the exact quantity of
quality product leaving that machine in a given time,
Speed
Efficiency,Efficiency is a ratio of output over input,but
in packaging production,this definition has many subtle
variations,For this discussion,efficiency is used to
describe a station’s or a packaging line’s actual operating
time over the available time,
The speed hierarchy would be as follows,
1,Design speed
2,Capacity
3,Run speed
4,Output rate
Straight-Line and Rotary Systems
Packaging machines such as fillers,cappers,and
labelers can be designed in straight-line and rotary
configurations,Straight-line machines usually index a
product into an operational station and then hold it there
until the operation is completed,
For example,intermittent-motion straight-line fillers
move containers under the filling heads and then stop for
the fill cycle,(Figure 18.1.) The machine may have one
fill head or several fill heads ganged together,
Straight-Line and Rotary Systems
Figure 18.1 Intermittent-motion straight-line filler
Straight-Line and Rotary Systems
Continuous-motion (rotary) machines do not index a
container into a station and stop,but instead feed the
container into a rotating turret,where the operational
heads work on the moving container,Rotary machines
require a timing screw on the conveyor feeding into the
starwheel to separate the containers to the correct pitch,
(Figure 18.2) The starwheel changes the direction of
container flow and inserts the containers into the filling
turret or back out onto the conveyor as the case may be,
Straight-Line and Rotary Systems
Figure 18.2 Rotary machines are able to operate at
higher speeds than intermittent machines,
Changeovers
Generally,the faster a machine operates,the more
complex the changeover,
For those applications where several different products
will be run on the same line,ease of changeover
becomes an important consideration,The simplest
change is when only the product needs to be replaced,
Changeovers can be an important part of output
calculations,Where changeovers are frequent,ease of
changeover,rather than actual machine speed,may
dictate machine choice,A fast machine that has an
excessive changeover time will be a handicap,
Changeovers
Ideally,changeovers should be possible to make critical
or time-consuming adjustments or settings off-line,Parts
and adjustments should be clearly marked for easy
identification and setup by personnel,All settings should
be quantified,
Fast Changeover
Introducing fast changeover to existing lines starts with
listing all the elements in a changeover,These should be
listed by time from the last sellable part of the old
production to the first sellable part made at production
speed on the new configuration,It includes both the hang
time and the run-in time,
Changeovers
Total changeover time can be grouped into four
main categories,
Preparation or organization,get parts,get tools,
locate mechanics/operators
Changeover,remove and remount change parts
Measurement,settings,calibrations,centering
Trial run,run-in,final adjustments
Changeovers
Make a histogram (a detailed bar chart showing where
time has been spent to effect the changeover),Focus on
the histogram's large elements,Determine ways to
accomplish time reductions,
Eliminate need for tools,
Externalize or "off-line" as much as possible,
Make all settings to a quantified scale,
Have a single documented procedure for all operators,
The ideal changeover takes no time,no tools,no
talent and you can sell, first off,,
Machine Controls
The motions of machine components are achieved,
timed,and controlled by various methods,They may be
mechanically actuated by levers,cams,chains,push
rods,or gears,
Motions can be controlled and implemented by
microswitches,timers,electromagnetic relays,hydraulics,
pneumatics,and electronic means,Each method has its
advantages and applications,
Maintenance is an important aspect of machine motion
and control systems,
Machine Controls
A machine runs best when all components are at their
optimum settings,These settings should be determined
and quantified and not left to operator discretion,
Microelectronics and microprocessors have provided
the packaging engineer with endless possibilities for
continuous monitoring of station variables such as fill
weight,throughput,production speed,and machine
settings,
Developing Custom Machinery
Periodically,packaging ideas surface for which no
machine has ever been built,Designing special-purpose
machines to perform totally new functions is an
especially arduous task,one not to be taken lightly,
The design of a unique machine usually goes through
the following stages,
1,Conceptual development (ideas for how each step will
be achieved)
2,Construction of station models
3,Creation of assembly and detail drawings for prototype
machine
Developing Custom Machinery
4,Construction of prototype machine
5,Test run of prototype machine in production
environment
6,Modification and improvement of prototype machine
7,Creation of assembly and detail drawings for
production machine
8,Construction and commissioning of production line
Depending on available expertise,some steps may be
shortened or circumvented,Design of special-purpose
machines is a high-risk activity and should be
approached with caution,
Upgrading Existing Equipment
Refurbishing existing in-house equipment,if it is
possible to do so,has definite benefits,
? You are working with proven technology (for
in-house equipment),
? There are no capital costs for upgrading
existing equipment,
? Initial training and commissioning problems
are reduced,
PACKAGING MACHINERY
第五单元 包装机械
Lesson 18
General Overview
第 18课 概述
Automated Production
Today,automated production is essential,Neither
volume nor product consistency can be achieved in any
other way,Increasing production in a cost-effective
manner is a difficult and complex undertaking,The
project engineer overseeing such a project must have
strong support from management,production,
maintenance,and vendors,Delays,errors,and higher
costs will result if this support is not totally integrated,
with all concerned playing an active role,
Automated Production
Increasing Production
Four options to increase production are,
Buy new state-of-the-art equipment,
Do something with existing equipment,
Buy refurbished equipment,
Hire a contract packager,
Factors that will influence this choice are as follows,
Availability of in-plant equipment
Market demand for the product
Automated Production
The time frame in which the product must be produced
Production volume
Quality standards
Equipment technology
Space constraint
Installation requirement
The New Production Line
The Packaging Machine Industry
Packaging machinery manufacture is a highly
specialized business that does not produce large
numbers of identical machines,
Products and packages come in such an
infinite variety of materials and forms that even
though a company may specialize in a particular
machine class,In this respect,packaging
machinery is a custom business,
The New Production Line
Given that a complete packaging line may consist of
six functional stations from six suppliers,connected by
conveyors and buffers made by still another supplier,it is
not likely that a new line can be plugged in and work
instantly and perfectly,New lines have to be debugged
and brought up to operating speed,Good production
engineers can usually coax a bit more speed out of a line
given time and experience with the process,
The New Production Line
General Considerations
Broad decisions as to machine class need to be made
early and are usually obvious,For example,
Will it be a dedicated machine or will it need
interchangeable parts?
Are particular standards of cleanliness and sterility
necessary?
Are active chemicals needing special corrosion
protection procedures a factor?
Should the machine flow be from left to right or right
to left?
The New Production Line
When examining candidate machines,remember that
good packaging lines accomplish their objective with a
minimum of vibration and noise,
The transfer and flow of product and material through
the production process should be smooth,with the
minimum of directional changes,
Before calling on machine suppliers,make a thorough
and critical analysis of what exactly needs to be
accomplished,
The New Production Line
Be realistic in the range of tasks that your machine will
be required to perform,and resist the temptation to
compromise the main objective,The more dedicated a
machine is,the more efficient it will be,
Capital outlay for machines can be heavy,
Effective servicing and parts supply is a key vendor
issue,
Speed
Terminology
The lack of specific and consistent terminology often
makes discussions of productivity confusing,For the
purpose of this discussion,the following definitions will
be used,
Packaging line,A group of integrated special-purpose
machines that combine product and package inputs and
produce a new product,The individual machines,each
performing a different function,are referred to as stations,
Input,Specific product and package items required for
package assembly,
Speed
Design speed,The theoretical capacity under perfect
running conditions,The speed of the machine as
designed,running empty,is the design cycle rate,
Capacity,The upper sustainable limit of quality
packages passing a point just before warehousing,
Run speed,The instantaneous operating rate at a point
in time,
Output,A packaging line’s output (designated Y) is the
exact quantity of quality product passing a point just
before warehousing or shipping in a given time,A
machine’s or station’s output is the exact quantity of
quality product leaving that machine in a given time,
Speed
Efficiency,Efficiency is a ratio of output over input,but
in packaging production,this definition has many subtle
variations,For this discussion,efficiency is used to
describe a station’s or a packaging line’s actual operating
time over the available time,
The speed hierarchy would be as follows,
1,Design speed
2,Capacity
3,Run speed
4,Output rate
Straight-Line and Rotary Systems
Packaging machines such as fillers,cappers,and
labelers can be designed in straight-line and rotary
configurations,Straight-line machines usually index a
product into an operational station and then hold it there
until the operation is completed,
For example,intermittent-motion straight-line fillers
move containers under the filling heads and then stop for
the fill cycle,(Figure 18.1.) The machine may have one
fill head or several fill heads ganged together,
Straight-Line and Rotary Systems
Figure 18.1 Intermittent-motion straight-line filler
Straight-Line and Rotary Systems
Continuous-motion (rotary) machines do not index a
container into a station and stop,but instead feed the
container into a rotating turret,where the operational
heads work on the moving container,Rotary machines
require a timing screw on the conveyor feeding into the
starwheel to separate the containers to the correct pitch,
(Figure 18.2) The starwheel changes the direction of
container flow and inserts the containers into the filling
turret or back out onto the conveyor as the case may be,
Straight-Line and Rotary Systems
Figure 18.2 Rotary machines are able to operate at
higher speeds than intermittent machines,
Changeovers
Generally,the faster a machine operates,the more
complex the changeover,
For those applications where several different products
will be run on the same line,ease of changeover
becomes an important consideration,The simplest
change is when only the product needs to be replaced,
Changeovers can be an important part of output
calculations,Where changeovers are frequent,ease of
changeover,rather than actual machine speed,may
dictate machine choice,A fast machine that has an
excessive changeover time will be a handicap,
Changeovers
Ideally,changeovers should be possible to make critical
or time-consuming adjustments or settings off-line,Parts
and adjustments should be clearly marked for easy
identification and setup by personnel,All settings should
be quantified,
Fast Changeover
Introducing fast changeover to existing lines starts with
listing all the elements in a changeover,These should be
listed by time from the last sellable part of the old
production to the first sellable part made at production
speed on the new configuration,It includes both the hang
time and the run-in time,
Changeovers
Total changeover time can be grouped into four
main categories,
Preparation or organization,get parts,get tools,
locate mechanics/operators
Changeover,remove and remount change parts
Measurement,settings,calibrations,centering
Trial run,run-in,final adjustments
Changeovers
Make a histogram (a detailed bar chart showing where
time has been spent to effect the changeover),Focus on
the histogram's large elements,Determine ways to
accomplish time reductions,
Eliminate need for tools,
Externalize or "off-line" as much as possible,
Make all settings to a quantified scale,
Have a single documented procedure for all operators,
The ideal changeover takes no time,no tools,no
talent and you can sell, first off,,
Machine Controls
The motions of machine components are achieved,
timed,and controlled by various methods,They may be
mechanically actuated by levers,cams,chains,push
rods,or gears,
Motions can be controlled and implemented by
microswitches,timers,electromagnetic relays,hydraulics,
pneumatics,and electronic means,Each method has its
advantages and applications,
Maintenance is an important aspect of machine motion
and control systems,
Machine Controls
A machine runs best when all components are at their
optimum settings,These settings should be determined
and quantified and not left to operator discretion,
Microelectronics and microprocessors have provided
the packaging engineer with endless possibilities for
continuous monitoring of station variables such as fill
weight,throughput,production speed,and machine
settings,
Developing Custom Machinery
Periodically,packaging ideas surface for which no
machine has ever been built,Designing special-purpose
machines to perform totally new functions is an
especially arduous task,one not to be taken lightly,
The design of a unique machine usually goes through
the following stages,
1,Conceptual development (ideas for how each step will
be achieved)
2,Construction of station models
3,Creation of assembly and detail drawings for prototype
machine
Developing Custom Machinery
4,Construction of prototype machine
5,Test run of prototype machine in production
environment
6,Modification and improvement of prototype machine
7,Creation of assembly and detail drawings for
production machine
8,Construction and commissioning of production line
Depending on available expertise,some steps may be
shortened or circumvented,Design of special-purpose
machines is a high-risk activity and should be
approached with caution,
Upgrading Existing Equipment
Refurbishing existing in-house equipment,if it is
possible to do so,has definite benefits,
? You are working with proven technology (for
in-house equipment),
? There are no capital costs for upgrading
existing equipment,
? Initial training and commissioning problems
are reduced,
