Lesson 19
The Packaging Line
第 19课 包装线
Pre-questions
? What is the Packaging Line?
? What are Requirements on the
Packaging Line?
content
? Introduction
? The Packaging Line
? Line Organization
? Packaging Materials
? Machine Capabilities
? Line Balancing
? Material and Container Characteristics
? Personnel
Introduction
1,Through the years,packages have developed from
gourds,large leaves,and other containers found in
nature into a group of mass-produced containers that are
frequently formed from synthetic materials,
? In the early 1900’s,most products were delivered to
customers in basic containers such as barrels,boxes,
jugs,bags,or wrapping paper,
? Since then,the vast assortment of new containers that
has been developed includes,
microwaveable pouches aseptic cartons
shrink wrappings squeezable plastic dispensers
attractively designed cartons,bags,and bottles
Introduction
2,The modern package serves a number of different
functions,
? to contain the product
? to protect the product,
? to attract attention
? to facilitate display
? to provide convenient dispensers
Introduction
3,The development of packaging machinery has made it
possible to efficiently produce packaged goods in large
quantities and a wide variety of forms,
? The many operations involved in the preparation of a
package are performed by a number of different
machines in a packaging line,These operations
include,
measuring and filling the product closing or sealing the
container applying a label
Checkweighing inspecting
preparing the individual packages for shipment
The Packaging Line
1,What is it?
? The packaging line consists of a group of packaging
machines with controls that make them work together
as one,
? Although the separate machines may have been
designed and built by different companies,they are
linked together and controlled as a synchronized unit,
? Packaging lines are made up of groups of packaging
machines in much the same way that the machines
are constructed from components,
The Packaging Line
2,What can it do?
? Converting the product it receives from the production
line into individual and grouped packages,These
packages provide protection for the products,
identification of the contents,decoration,advertising,
instructions,and a means for distribution through the
system and eventually to the user,
The Packaging Line
? In many plants,the packaging line is physically attached
to the production line so that product is fed directly into
the packaging line by a conveyor system,In these
systems,the production and packaging lines operate as
an integrated system,However,the production and
packaging lines are frequently separated,Some
operations ship bulk product to a contract packager in a
remote location,
? The packaging line receives the product,containers,lids,
adhesives,labels,wrapping material,and other materials
that are needed for the package,The machines use
these materials to form,fill,seal,and deliver a complete
package,
The Packaging Line
[For example] a bottled beer procedure,
? The bottles are fed into its packaging line through a
uncasing machine
? The bottles are cleaned
? The liquid filler measures the beer and fills the bottle
? The bottle is capped
? The filled bottle is inspected
? The bottled beer is sterilized
? A label is applied
? The bottled beer is inserted into a box
? The box is closed
The Packaging Line
? Product codes and dates are applied
? The boxes are gathered
? The boxes are marked,sealed,and loaded onto
pallets for shipment
This entire operation takes place on a packaging line
which contains 10 or more different machines
operating together,
Line Organization
1,Line and Packaging Machines
? Some packaging lines have only a small number of
manually operated packaging machines
? Many packaging lines contain a group of automated
packaging machines that operate at high speeds
? The individual packaging machines are connected by
conveyors or other product feed devices and are
adjusted,timed,and controlled so that they work
together,
Line Organization
? A problem in one machine can affect the operation of
all the other machines in the line,The packaging
machines that make up a line are frequently designed
and built by different companies,Adaptations or
special provisions may be required to synchronize
their operations,
2,Line and Packaging Quality
? The operation of a packaging line and the quality of
the package it produces is dependent upon the
interaction of
the product the containers or packaging material
the machine capabilities the operator’s skill
the machine maintenance
Line Organization
? The product’s physical characteristics can make it easy
or difficult to package
- A product that tends to lump or become sticky as the
result of changes in the humidity or production process
can be difficult to fill and require special checkweighing
or monitoring equipment;
- Fragile products may require special handling to
prevent breakage;
- Carbonated beverages require a sealed filler that does
not allow the CO2 to escape;
- Corrosive or hazardous products may require special
measures to protect the operators and packaging
machinery,
Packaging Materials
? The machinability of the packaging materials or
containers has a strong influence on the machine
operation;
? Machinability is the ease with which a product,
packaging material,or container moves through the
line and produces a good quality package;
A,Containers that are difficult to hold in position,webs
that jam,and heat-seal materials that melt onto the
machine are considered to have poor machinability;
B,A film web with one type of coating may move
through the machine with no difficulty,The same film
with a different coating may bunch up,wrinkle,tear,
or cause other types of problems;
Packaging Materials
C,A folding carton that absorbs moisture from the
atmosphere or has irregular flaps can cause the
machine to jam or tear the carton;
D,An adhesive containing too much solvent may
require additional drying time;
E,A lightweight bottle that topples over will stop or jam
the machine,
Machine Capabilities
1,Speed
? A packaging line cannot be expected to produce an
operating speed or deliver a quality of package that
exceeds the capability of any of the machines in the line
? The limitations of the line are determined by the slowest
or least-accurate machine in the line;
? Each packaging machine is designed to operate most
effectively within a particular speed range,with
particular types of products,and under given sets of
conditions,
Machine Capabilities
2,The Machines in a Packaging Line
? How to Select,
to handle the product,containers,and packaging material
Speed versatility adaptability adjustability
Accuracy dependability to forgive being misused
? Integrated by conveyors,control units,and timing
mechanisms;
? Some lines operate all the machines from a common
power source;
? Other lines use machines with independent power
sources;
Machine Capabilities
? Some machines may perform functions that have
unique power requirements including 440 V,220 V,3
Phase,and DC electrical power;
? Machines may require specific compressed air
pressure for operating machine components or
controls,
Line Balancing
Definition,
? The line must be balanced and timed so that machines
will operate as one integrated unit;
? Timing the line sets all the machines to run at the
same or compatible speeds,and it starts and stops
each operation at the proper time;
? When one machine is running too fast,excess product
backs up down the line,When a machine is too slow,
the line backs up,and machines down the line do not
receive enough product;
Line Balancing
How to Balance a Line,
? Selecting the machines and/or adjusting the speeds
and starting times so that they operate together to
produce a smooth flow;
? Conveyors,accumulators,and feed control systems
can be used to store excess production and
compensate for unevenness in the flow when one of
the machines is shut down for short periods of time,
Material and Container Characteristics
1,Converters,
? Many packaging materials and containers are
prepared for the packaging line by the converters who
supply the material;
? Converters are companies that combine and process
materials to make them ready for use on the
packaging line;
[For example]
? The converters
1,laminate film,foil,or other web materials,apply
protective coatings,and print them ready to load onto
a machine that makes pouches for packaging a
particular product;
Material and Container Characteristics
2,convert corrugated board into knock-down cases and
convert paperboard into folding cartons;
3,print labels and decorative designs on them;
4,coat,laminate,and print webs of wrapping material;
5.print rolls of labels;
6.perform many operations involved in producing
packaging materials and containers used on the
packaging line,
Material and Container Characteristics
2,Container Characteristics
? Selecting a new container or changing the design of
an existing one can have several effects on the
operation of the machinery in a packaging line,When
the container design is changed,the following should
be considered,
Cost Speed Quality
[For example]
? Changing a syrup container from a round can with a
center neck to a rectangular can with the opening at
one end may produce a package that is
more attractive / easier to use / increase sales
Material and Container Characteristics
? However,it can also result in a more expensive container
that
? is difficult to orient on the line / reduces machine speeds
? increases spillage / requires purchasing a new labeler
? That is,it may be a very advantageous change,or it
may cost more than it is worth,Failing to consider all
the variables that are operating in a packaging line
can result in undesirable decisions,
? Container Characteristics That Affect Machine
Operations,
variability in size smoothness of the lips
rigidity of a folded carton shape of containers
positions of pouring spouts positions of handles
weight of the container
Material and Container Characteristics
3,Material Characteristics
? Film and other web materials may have a tendency to
pucker,tear,or stretch;
? The thickness of the material and its coatings can
drastically change its machinability;
? Changing from a lightweight material to a heavier one
may cause problems if the machine is not adjusted for
the new material;
? Improper storage can make some packaging materials
difficult to handle;
Material and Container Characteristics
[For example]
a,Folding carton blanks and other paper and paperboard
products warp and become difficult to run when they
are exposed to excessive humidity;
b,Some laminated web materials are so sensitive to
moisture and temperature changes that they are
stored in climate-controlled rooms during extreme
weather conditions,
Material and Container Characteristics
c,Tall,slender bottle caps are difficult to handle and
frequently require cap feeders with pockets that hold
the caps upright as they are moved into position over
the containers,Some cap feeders use rising pins to
guide these caps into the delivery chute,Special
capper chucks with protective jaws may be required
for painted or decorated caps that may be easily
scratched or marred by rough handling,
Personnel
? A surprisingly large number of people in different types
of jobs make decisions and initiate actions that affect
the operation of the packaging line,
-The operators of the production line determine the amount
of product that the packaging line will receive,the rate and
evenness of the product flow,and the consistency of the
product's handling characteristics;
-The packaging machine adjuster sets up the machine
and makes the adjustments that control its operation;
-The packaging machine operator controls the minute-to-
minute operation;
-The inspector determines when the packages are not
acceptable and machine adjustments are needed;
Personnel
-The packaging machinery mechanic troubleshoots and
repairs the machine when it is not functioning properly,
-Salespeople produce orders that enable the line to run;
-The scheduler determines the sequence of jobs and the need
for changeovers;
-The packaging line supervisors oversee the operations and
decide who will work and when,
-Packaging engineers or packaging specialists select the
package designs and materials and influence the selection of
the machines that will be included in the packaging line;
Personnel
-The purchasing department buys the packaging materials
And containers;
-The materials handler keeps the line supplied with the
materials as they are needed,
The Packaging Line
第 19课 包装线
Pre-questions
? What is the Packaging Line?
? What are Requirements on the
Packaging Line?
content
? Introduction
? The Packaging Line
? Line Organization
? Packaging Materials
? Machine Capabilities
? Line Balancing
? Material and Container Characteristics
? Personnel
Introduction
1,Through the years,packages have developed from
gourds,large leaves,and other containers found in
nature into a group of mass-produced containers that are
frequently formed from synthetic materials,
? In the early 1900’s,most products were delivered to
customers in basic containers such as barrels,boxes,
jugs,bags,or wrapping paper,
? Since then,the vast assortment of new containers that
has been developed includes,
microwaveable pouches aseptic cartons
shrink wrappings squeezable plastic dispensers
attractively designed cartons,bags,and bottles
Introduction
2,The modern package serves a number of different
functions,
? to contain the product
? to protect the product,
? to attract attention
? to facilitate display
? to provide convenient dispensers
Introduction
3,The development of packaging machinery has made it
possible to efficiently produce packaged goods in large
quantities and a wide variety of forms,
? The many operations involved in the preparation of a
package are performed by a number of different
machines in a packaging line,These operations
include,
measuring and filling the product closing or sealing the
container applying a label
Checkweighing inspecting
preparing the individual packages for shipment
The Packaging Line
1,What is it?
? The packaging line consists of a group of packaging
machines with controls that make them work together
as one,
? Although the separate machines may have been
designed and built by different companies,they are
linked together and controlled as a synchronized unit,
? Packaging lines are made up of groups of packaging
machines in much the same way that the machines
are constructed from components,
The Packaging Line
2,What can it do?
? Converting the product it receives from the production
line into individual and grouped packages,These
packages provide protection for the products,
identification of the contents,decoration,advertising,
instructions,and a means for distribution through the
system and eventually to the user,
The Packaging Line
? In many plants,the packaging line is physically attached
to the production line so that product is fed directly into
the packaging line by a conveyor system,In these
systems,the production and packaging lines operate as
an integrated system,However,the production and
packaging lines are frequently separated,Some
operations ship bulk product to a contract packager in a
remote location,
? The packaging line receives the product,containers,lids,
adhesives,labels,wrapping material,and other materials
that are needed for the package,The machines use
these materials to form,fill,seal,and deliver a complete
package,
The Packaging Line
[For example] a bottled beer procedure,
? The bottles are fed into its packaging line through a
uncasing machine
? The bottles are cleaned
? The liquid filler measures the beer and fills the bottle
? The bottle is capped
? The filled bottle is inspected
? The bottled beer is sterilized
? A label is applied
? The bottled beer is inserted into a box
? The box is closed
The Packaging Line
? Product codes and dates are applied
? The boxes are gathered
? The boxes are marked,sealed,and loaded onto
pallets for shipment
This entire operation takes place on a packaging line
which contains 10 or more different machines
operating together,
Line Organization
1,Line and Packaging Machines
? Some packaging lines have only a small number of
manually operated packaging machines
? Many packaging lines contain a group of automated
packaging machines that operate at high speeds
? The individual packaging machines are connected by
conveyors or other product feed devices and are
adjusted,timed,and controlled so that they work
together,
Line Organization
? A problem in one machine can affect the operation of
all the other machines in the line,The packaging
machines that make up a line are frequently designed
and built by different companies,Adaptations or
special provisions may be required to synchronize
their operations,
2,Line and Packaging Quality
? The operation of a packaging line and the quality of
the package it produces is dependent upon the
interaction of
the product the containers or packaging material
the machine capabilities the operator’s skill
the machine maintenance
Line Organization
? The product’s physical characteristics can make it easy
or difficult to package
- A product that tends to lump or become sticky as the
result of changes in the humidity or production process
can be difficult to fill and require special checkweighing
or monitoring equipment;
- Fragile products may require special handling to
prevent breakage;
- Carbonated beverages require a sealed filler that does
not allow the CO2 to escape;
- Corrosive or hazardous products may require special
measures to protect the operators and packaging
machinery,
Packaging Materials
? The machinability of the packaging materials or
containers has a strong influence on the machine
operation;
? Machinability is the ease with which a product,
packaging material,or container moves through the
line and produces a good quality package;
A,Containers that are difficult to hold in position,webs
that jam,and heat-seal materials that melt onto the
machine are considered to have poor machinability;
B,A film web with one type of coating may move
through the machine with no difficulty,The same film
with a different coating may bunch up,wrinkle,tear,
or cause other types of problems;
Packaging Materials
C,A folding carton that absorbs moisture from the
atmosphere or has irregular flaps can cause the
machine to jam or tear the carton;
D,An adhesive containing too much solvent may
require additional drying time;
E,A lightweight bottle that topples over will stop or jam
the machine,
Machine Capabilities
1,Speed
? A packaging line cannot be expected to produce an
operating speed or deliver a quality of package that
exceeds the capability of any of the machines in the line
? The limitations of the line are determined by the slowest
or least-accurate machine in the line;
? Each packaging machine is designed to operate most
effectively within a particular speed range,with
particular types of products,and under given sets of
conditions,
Machine Capabilities
2,The Machines in a Packaging Line
? How to Select,
to handle the product,containers,and packaging material
Speed versatility adaptability adjustability
Accuracy dependability to forgive being misused
? Integrated by conveyors,control units,and timing
mechanisms;
? Some lines operate all the machines from a common
power source;
? Other lines use machines with independent power
sources;
Machine Capabilities
? Some machines may perform functions that have
unique power requirements including 440 V,220 V,3
Phase,and DC electrical power;
? Machines may require specific compressed air
pressure for operating machine components or
controls,
Line Balancing
Definition,
? The line must be balanced and timed so that machines
will operate as one integrated unit;
? Timing the line sets all the machines to run at the
same or compatible speeds,and it starts and stops
each operation at the proper time;
? When one machine is running too fast,excess product
backs up down the line,When a machine is too slow,
the line backs up,and machines down the line do not
receive enough product;
Line Balancing
How to Balance a Line,
? Selecting the machines and/or adjusting the speeds
and starting times so that they operate together to
produce a smooth flow;
? Conveyors,accumulators,and feed control systems
can be used to store excess production and
compensate for unevenness in the flow when one of
the machines is shut down for short periods of time,
Material and Container Characteristics
1,Converters,
? Many packaging materials and containers are
prepared for the packaging line by the converters who
supply the material;
? Converters are companies that combine and process
materials to make them ready for use on the
packaging line;
[For example]
? The converters
1,laminate film,foil,or other web materials,apply
protective coatings,and print them ready to load onto
a machine that makes pouches for packaging a
particular product;
Material and Container Characteristics
2,convert corrugated board into knock-down cases and
convert paperboard into folding cartons;
3,print labels and decorative designs on them;
4,coat,laminate,and print webs of wrapping material;
5.print rolls of labels;
6.perform many operations involved in producing
packaging materials and containers used on the
packaging line,
Material and Container Characteristics
2,Container Characteristics
? Selecting a new container or changing the design of
an existing one can have several effects on the
operation of the machinery in a packaging line,When
the container design is changed,the following should
be considered,
Cost Speed Quality
[For example]
? Changing a syrup container from a round can with a
center neck to a rectangular can with the opening at
one end may produce a package that is
more attractive / easier to use / increase sales
Material and Container Characteristics
? However,it can also result in a more expensive container
that
? is difficult to orient on the line / reduces machine speeds
? increases spillage / requires purchasing a new labeler
? That is,it may be a very advantageous change,or it
may cost more than it is worth,Failing to consider all
the variables that are operating in a packaging line
can result in undesirable decisions,
? Container Characteristics That Affect Machine
Operations,
variability in size smoothness of the lips
rigidity of a folded carton shape of containers
positions of pouring spouts positions of handles
weight of the container
Material and Container Characteristics
3,Material Characteristics
? Film and other web materials may have a tendency to
pucker,tear,or stretch;
? The thickness of the material and its coatings can
drastically change its machinability;
? Changing from a lightweight material to a heavier one
may cause problems if the machine is not adjusted for
the new material;
? Improper storage can make some packaging materials
difficult to handle;
Material and Container Characteristics
[For example]
a,Folding carton blanks and other paper and paperboard
products warp and become difficult to run when they
are exposed to excessive humidity;
b,Some laminated web materials are so sensitive to
moisture and temperature changes that they are
stored in climate-controlled rooms during extreme
weather conditions,
Material and Container Characteristics
c,Tall,slender bottle caps are difficult to handle and
frequently require cap feeders with pockets that hold
the caps upright as they are moved into position over
the containers,Some cap feeders use rising pins to
guide these caps into the delivery chute,Special
capper chucks with protective jaws may be required
for painted or decorated caps that may be easily
scratched or marred by rough handling,
Personnel
? A surprisingly large number of people in different types
of jobs make decisions and initiate actions that affect
the operation of the packaging line,
-The operators of the production line determine the amount
of product that the packaging line will receive,the rate and
evenness of the product flow,and the consistency of the
product's handling characteristics;
-The packaging machine adjuster sets up the machine
and makes the adjustments that control its operation;
-The packaging machine operator controls the minute-to-
minute operation;
-The inspector determines when the packages are not
acceptable and machine adjustments are needed;
Personnel
-The packaging machinery mechanic troubleshoots and
repairs the machine when it is not functioning properly,
-Salespeople produce orders that enable the line to run;
-The scheduler determines the sequence of jobs and the need
for changeovers;
-The packaging line supervisors oversee the operations and
decide who will work and when,
-Packaging engineers or packaging specialists select the
package designs and materials and influence the selection of
the machines that will be included in the packaging line;
Personnel
-The purchasing department buys the packaging materials
And containers;
-The materials handler keeps the line supplied with the
materials as they are needed,
