Food & Beverage Asia June/July 2020

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54 PROCESSING AND PACKAGING the entire plant. The powder is first filled into corresponding bags in parallel in two form-fill and seal machines, then fed on two tracks to a horizontal cartooning machine. Here, one or two bags are placed in a folding box and provided with a dosing spoon before the box is closed. The readyto-load boxes are then taken to the final packaging machine and packed into a transport carton. The last station is then the customer’s palletising system. Values stored in the control system All 40 adjustment points along the line must always be adapted to the new dimensions according to the respective packaging sizes. Most of the adjustment points are located in the cartoner and end-of-line packaging area, less so in the tubular bag machine. When a new size is needed, the corresponding recipe is selected in the controller, whereby all electronic position indicators receive the new setpoints directly via the IO link interface and display them on the backlit display. The LEDs of the display immediately switch to red, as the current position is now no longer correct. The operator then goes on to mechanically adjusts all Cartoning machines have numerous adjustment points that can be adjusted during size changeover with the aid of electronic position indicators corresponding points to the new values – another ergonomic advantage: The AP10 indicates the direction to the setpoint via the LEDs and the LCD with corresponding arrows, to make it easy to visualise where the operator has to move to. If the position and setpoints then match exactly, the LED display changes to green: Position reached. This is how all the red position indicators are moved in order to finally be able to start the new product. The advantages are that all values are already available electronically, and are transmitted directly to the position indicators. Moreover, changeover is faster as well as safer because the feedback of the LED lights is clear. The system can only be restarted if all the corresponding position indicators light up green. Scope for fine adjustment In this case, the position indicators for the setpoints are given a specific tolerance range based on a nominal value. The operator has the possibility of making fine adjustment within this, and the position indicators light up green. If the operator leaves the area, the display switches to red. The ETIL end-of-line packaging machine for trays with lids enables a “precise and product-friendly” packaging process. Electronic Siko position indicators for monitored size changeover can be integrated as an option This margin can be advantageous in the event of packaging material fluctuations in the carton area. If the temperature of the hot-melt glue fluctuates or a cardboard box is slightly more creased, it may be useful to slightly adjust the guides or a contact pressure by a folding tool, for example. According to Hamel, this fine adjustment is welcomed by the operators who know the plant and product best, as he elaborated, “The tolerance range allows the operators to make an independent assessment of the situation and gives them FOOD & BEVERAGE ASIA JUNE / JULY <strong>2020</strong>
PROCESSING AND PACKAGING 55 scope of action. This makes the processes more efficient, and the employee feel more involved.” IO link is on the advance IO link is a communication standard that is gaining ground internationally, and those who used IO link for their automation benefit from many advantages, Siko highlighted. As a communication protocol, IO link is manufacturer-independent. Accordingly, devices and masters can be developed as communication participants. Option that works Electronic position indicators for monitored size changeover are optionally available for all Rovema machines and systems. The customer of the packaging plant for infant formula had all 40 adjustment points equipped with AP10 displays, because the Rovema advantages – faster changeover times and less documentation effort, because all information is electronically stored and retrievable. Siko pointed out another advantage, which is the significantly increased process reliability due to the red/green LED system; eliminating the occurrence of incorrect settings. The company further revealed that 50% of Rovema customers use this option for monitored size changeover in cartooning and end packaging technology. FBA Integration is possible via simple pointto-point connections at the network level, and the wiring effort is lower compared to fieldbus interfaces. The AP10 displays are regarded as IO link devices, each of which is connected to an IO link master, which usually has eight ports. From the master, communication with the controller is via another protocol, in this case, Sercos III. Explaining the reasons for not using Ethernet/IP throughout for communication, Müller explained, “IO link is the much more cost-effective interface, which also makes significantly lower demands on the wiring, and is thus also easily connected.” Hamel added, “We were very pleased that the first commissioning worked right away without a lot of cabling work and with simple parameterisation and integration into the control system.” According to Müller, there is also a simple diagnostic function. IO link shows which device may have a fault or needs to be optimised. For this purpose, the position indicators can be exchanged during operation without having to open up an entire network ring. The affected device can be disconnected and replaced by a new one due to the star-shaped plug connection to the IO link master. The parameterisation can then be loaded from the IO link master into the new device and thus accepted.
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JUNE / JULY 2020 www.foodbeverageas
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Food & Beverage Asia June/July 2020

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