BEST PRACTICES FOR EMPLOYEE HYGIENE

Meritech, Golden, Colo., showcased its hygiene programs designed to eliminate cross-contamination risk and ultimately prevent product recalls in facilities worldwide.  

Meritech manufactures CleanTech, what is said to be the world's only fully automated handwashing system. CleanTech performs a CDC standard hand wash in just 12 seconds, removes 99.9% of pathogens from hands while using 75% less water and creates 75% less waste than traditional manual handwashing methods.

Meritech
800-932-7707
www.meritech.com

AUGMENTED REALITY, REMOTE SUPPORT TECHNOLOGY FOR CONTAINER HANDLING SYSTEMS

Morrison Container Handling Solutions, Glenwood, Ill., demonstrated its innovative remote support technology.

The enhancement to the Support Built In doctrine consist of special glasses equipped with augmented reality (AR) technology that enables livestreaming of the customer’s facility, so Morrison can diagnose and guide in real-time for quick response to questions that may arise in the set-up, operation and maintenance of container handling systems. Additionally, the glasses provide PDF viewing, language translation, photo capture and sharing, video viewing, are safety rated and can even be programmed to guide changeover operations specific to the customer’s application.

This technology also uses Hololens AR, where the headset allows customers to physically interact with a virtual container handling solution, seeing it in life size or tabletop to truly picture how it will fit into an existing or new line.

The Smart Combiner and Divider System, for instance, is said to provide the most compact combiner and divider on the market. This custom drive assembly joins multiple lanes of product into one single flowing lane for easy changeover, little line space and the ability to mount to existing conveyors. The photoeyes sort based on color, understanding the direction each container must go in order to create the correct multi-pack and communicating that to the servo motor. The system can register up to three different containers, so users have a variety of options for multi-packs.

The Morrison Auto Adjust Rails come within 1mm of accuracy for individual bottles and 5mm of accuracy for case handling. Additionally, the hassle of supplying constant air pressure disappears because with this system, users only supply air pressure to create the needed positioning. The HMI will hold the set position; no need for operators to walk the line for repositioning. Morrison Auto Adjust Rails reduce downtime, so companies can increase line efficiency. With a few clicks of a button, operators can change over to a new product and maintain accuracy with positive control of products for up to 43 different SKUs.

The Model 60 Can Opener is an all-in-one can opening system that standardizes the canning procedure. Infeed timing screws allow manufacturers to process cans up to 60 cpm while reducing labor demands and creating positive control. The heavy-duty, stainless-steel systems are washdown friendly and provide complete processing functionality in a single station. Plus, the optional system can be built in to catch excess metal and crush cans for recycling, eliminating the need for additional labor and space.

Servo-controlled infeed allows intermittent feed of containers smoothly reestablishing prime up to 600 cpm. When backlog is low, the screw stops. Start at speeds up to 600 cpm can stop containers up to 2,000 cpm, reducing container damage while increasing production uptime, with no need to stop the machine to reestablish feed. Quick changeover designs are also available.

Morrison Container Handling Solutions
708-756-6660
https://morrison-chs.com

ADVANCED TRAY SEALING SOLUTIONS

Proseal, UK, showcased its advanced tray sealing solutions.

Models range from the semi-automatic Proseal GTR, ideal for smaller scale enterprises and new product development, to the high-speed, fully automatic Proseal GT6e with a maximum speed of 96 vacuum-gas packs per minute or 160 atmospheric seal packs per minute on an 8-impression tool.

The company’s entire range of tray sealing machines is readily equipped to help cold food and beverage manufacturers adopt new pack formats without additional investment.

Proseal also demonstrated the Halopack tray, what is said to be the first fully hermetic cardboard modified atmosphere packaging (MAP). Halopack trays are produced on the Proseal SKR machine, and the board base material is made from over 90% recycled cardboard. Halopack incorporates high barrier properties that maintain product quality, and with the right conditions, can extend shelf life.

Proseal also highlighted its ability to handle and seal extremely lightweight plastic trays, while reducing the amount of plastic by up to 42%.

In addition, the company demonstrated a variety of different pack sealing formats, including a new skin packaging technology called Skin², which increases cycle speeds over existing skin processes while reducing unit and equipment costs. 

Proseal’s flexible ‘e’ range of tray sealing machines can handle every format of tray sealing, with the ability to introduce or remove these features at any time. This gives food producers the flexibility to easily switch between packaging formats during normal production.

The company’s Eseal technology is featured on all automatic tray sealers, helping customers meet the stringent quality requirements of the food retail sector while achieving a 92% reduction in energy usage.

Furthermore, Proseal exhibited its advanced OC Conveyor feeding a Proseal GT1e machine to illustrate the production efficiencies of an integrated conveyor and tray sealer solution.

And, the LC1 Lid-clipping machine is a fully automatic, in-line lid-placing, denesting and patent-pending tamping system that utilizes recyclable packaging. It can accept trays from any conveyors, such as clip lids onto film-sealed trays, and take trays directly from a filling conveyor when no film lid is required. Through the use of these features to avoid any loading errors, the LC1 system can be fully integrated with other in-line equipment, including upstream tray-sealing machines.

Proseal UK Ltd.
+44 (0) 1625 856600
www.proseal.com

MODULAR CONVEYOR STATION

Regal Beloit Corp., Beloit, Wis., showcased its MODSORT modular transfer and diverter station, which can accommodate a wide variety of products in any direction while eliminating the need for a lift or pneumatics while being integrated into new or existing material handling systems. The MODSORT conveyor station features the System Plast 2253RT roller top belt, which allows the conveyor station to uniquely transfer and divert packages based on the sphere’s vector speed and direction while also featuring a 1-inch, on-center sphere array for very small packages to be diverted. The matrix of freely rotating balls imbedded into a continuous flat belt allows the rolling top belt station to divert and transfer products of any kind by using precise, controlled and impact-free motion to divert and transfer products on motorized conveyor lines. The station can divert on the fly or stop and divert at a 90-degree angle, making it ideal for polybags and small packages. MODSORT conveyor stations can be placed end to end to create a medium-rate sorter or integrated with conveyors to create transfer stations within conveyor systems. Customization is possible for picking and packing stations within a modern distribution center. Additionally, retrofitting the station into existing conveyor systems is also possible. The MODSORT conveyor station also helps achieve energy savings between 50-60% compared to traditional conveyors when integrated with a motorized roller-based conveyor system due to its low weight and friction. The conveyor station features:

• Motorized drive rollers (MDR) and controls that employ run-on-demand technology.
• 24-volt DC motor and controls that allow flexibility in wiring and control.
• The ability to divert small packages and boxes.
• No pneumatics, lifts or Z-direction position feedback devices are needed.
• Safe, energy-efficient, quiet and low-maintenance operation.
• Controls that allow stand-alone programming or can interface to a PLC via network.
• No gaps or pinch points anywhere on the roller-free belt, i.e., workers have a much lower risk of injury.

Regal Beloit also showcased its Perceptive Technologies services, which include a complete offering of technical solutions to help companies be proactive — rather than reactive — when it comes to sustaining their maintenance processes. The Perceptive Technologies services include:

• Transient torque monitoring for fatigue life prediction and efficiency.
• Vibration monitoring and analysis.
• Infrared thermography.
• Ultrasonics.
• Lubrication analysis.
• Motor current signature analysis

Operators can use the online monitoring system via the app on a tablet, smartphone or computer to determine the existing state of a component and then measure effects of changes in products or processes. If the technology determines that a component may
soon malfunction, personnel can schedule maintenance or order and ship a new part before equipment failure occurs.

Regal Beloit Corp.
608-364-8800
www.regalbeloit.com

FILMS & NON-WOVENS FOR FLEXIBLE PACKAGING

RKW Group, Germany, displayed its wide range of special engineered films and non-wovens for a large variety of applications in the flexible packaging industry.

For example, the company’s sustainable line encompasses films that can be used to produce fully recyclable stand-up pouches, and contain various degrees of recycled post-consumer raw material (PCR). RKW is also investing in new technologies that enable the development of unique films that offer new opportunities in saving raw materials.

In addition, RKW presented the latest developments in its film portfolio, which includes mainly monolayer, multi-layer barrier films such as EVOH and/or nylon and easy-tear films.

The RKW portfolio also covers a wide range of films for packaging applications such as hybrid shrink-/stretchhoods and RKW ProVent bags for powdery goods.

Furthermore, the company is investing close to $19 million in its Franklin, Ky., production site to strengthen the company’s position in North America. The North American site expansion includes the construction of a new 30,000-square-foot manufacturing and warehouse facility and new, state-of-the-art equipment.

RKW Group
+49-(0)6233-8709-0
www.rkw-group.com

LABEL APPLICATOR FOR PRINT-AND-APPLY LABELING

ID Technology, a ProMach product brand, Fort Worth, Texas, introduced its CrossMerge label applicator module for print AND apply labeling. Ideal for high-volume secondary packaging lines, the patent-pending CrossMerge technology increases label output, simplifies mechanics and improves print quality and barcode readability. By rotating the print head, CrossMerge optimizes the conditions for both barcode printing and label application. To produce well-defined edges and ensure the best scores when verified, the bars of linear barcodes run parallel to the direction of feed (called picket fence printing), rather than perpendicular (called ladder printing). Unlike traditional print-and-apply labelers that must produce linear barcodes in the ladder direction to apply GS1-compliant labels in landscape orientation, CrossMerge prints barcodes in the picket fence direction and applies labels in landscape orientation. Rotating the print head also enables CrossMerge to increase output and decrease print speed to reduce print head wear and tear and further improve print quality. For example, CrossMerge customers can use 4x2 labels, and dispense labels at twice the rate or slow the print speed in half to improve print quality and double the life of the print head.

ID Technology also introduced the patent-pending TiltTouch, designed to apply one or two GS1-compliant barcode labels to shipping cases, trays and shrink-wrapped bundles at high output speeds. When using TiltTouch and two 4x2-inch labels, a total of only 4 inches of material needs to run through the printer, which helps to reduce print time and wear on the printer, as well as support printing barcodes in the preferred orientation. A further advantage of TiltTouch is that feeding the labels in this orientation greatly increases the number of labels on the roll, leading to improved efficiency with less downtime for label roll changes. The TiltTouch module is powered by a pair of precision pneumatic cylinders, one with a longer stroke than the other. The shorter cylinder moves the applicator to apply the label on the side of the item. For labeling the leading or trailing face of the package, the two cylinders work together to apply a label as quickly as possible. ID Technology’s refined applicator pad technology keeps the applicator from coming into contact with the product at any point of the operation, as the labels are gently controlled by a jet of air. The moving components of TiltTouch are designed to have minimal mass, allowing for smooth, fast motion and wear reduction.

ID Technology
888-438-3242
www.idtechnology.com

CHILD-RESISTANT ZIPPER CLOSURES

Zip-Pak, Manteno, Ill., debuted two new innovations, resulting from the in-depth research and ingenuity of the company’s Engineering and Innovation Center.

The Safety-Lok Child-Resistant Press-to-Close zipper keeps contents fresh, while protecting children from potentially dangerous products. Safety-Lok Child-Resistant Press-to-Close features a hermetic seal that maintains package integrity and extends product shelf life. The unique tabbed profile provides resistance for younger children, yet provides easy accessibility for older consumers challenged by child-resistant packaging. Plus, it’s compliant with CFR - Title 16 Part, 1700 standards.

The Safety-Lok Child-Resistant Slider features an intuitive 1-step opening from any position, and is compliant with CFR and ISO standards.

Also showcased was ValvPak, a revolutionary patented flexible valve technology that provides controlled dispensing and spill-proof containment of liquids in flexible packaging. A discrete flexible valve yields when pressure is applied to a pouch’s product compartment, thus enabling controlled dispensing. When squeeze-pressure is released, the valve reoccupies and closes the dispensing channel. Compared to a rigid bottle or a pouch with a plastic cap or closure, ValvPak is an e-commerce-ready solution that doesn’t require any overwraps or extra packaging.

Zip-Pak, a division of Illinois Tool Works
800-488-6973
www.zippak.com

AUTOMATED PACKAGING TECHNOLOGY

Coesia Group, Covington, Ky., showcased its best-of-breed automated packaging technology. The combined strength of VOLPAK, R.A JONES (formerly known Oystar North America, following the acquisition) and FLEXLINK offers pouching, cartoning, conveying and palletizing equipment to optimize consumer goods and other product packaging lines – all from a single global organization.

On display was Remote Assistance, the company’s technology-driven service solution that uses high-quality audio, live video, file-sharing, remote PLC interface and augmented reality for faster, more effective equipment diagnosis. Remote Assistance combines technology like smart glasses, tablets or smartphones with an IT platform to connect on-site personnel with Coesia experts. This enhanced collaboration allows packaging operations to resolve issues faster and maximize uptime.

VOLPAK SI series horizontal form-fill-seal pouching machine is packed with smart connectivity features and offers the versatility to handle new packaging designs and a variety of pouch materials.

R.A JONES Criterion CLI series cartoner offers a compact footprint and flexible packaging line layouts to fit in tight spaces, while handling the largest range of carton sizes.

FLEXLINK X70X stainless-steel conveyor offers a modular solution, designed with minimal dirt pockets and rounded surfaces for better drainage and cleanliness.

FLEXLINK RC10 palletizing system uses a collaborative robot to work alongside employees at the end of packaging lines, without the need of a cage of fence. This system can handle cartons weighing up to 16 pounds.

Coesia Group
859-341-0400
www.coesia.com

HYGIENIC INDUSTRIAL CONTROL HARDWARE

Rockwell Automation, Milwaukee, Wis., showcased how food manufacturers and packagers can better protect the integrity of their products using new hygienic industrial control hardware.

The new Allen-Bradley Kinetix VPH hygienic servo motors and a new stainless-steel version of the Allen-Bradley PanelView Plus 7 graphic terminal both help minimize contamination during production and ease compliance.

The stainless-steel PanelView terminal can be used on a machine in a “splash” or contaminant zone without the need to be covered or isolated. This helps protect product quality and simplifies the cleaning processes, while removing obstructions to the human machine interface, so operators can better monitor production. This product is said to be the industry’s first general-purpose HMI terminal certified by the National Sanitation Foundation (NSF). It has an ingress-protection rating of IP69K to support high-pressure, high-temperature chemical washdowns. It also uses a food-grade silicone gasket with a distinct blue color to help production workers notice if it’s been damaged and needs to be replaced.

The new Kinetix VPH hygienic servo motors can improve machine reliability while enhancing consumer safety by meeting stringent hygienic standards. The hygienic design, including high-grade stainless-steel housing and a smooth surface, can withstand washdowns and reduce the risk of contamination. The servo motors are designed per the EHEDG and 3-A sanitary standards, and are IP69K rated and NSF certified. They seamlessly integrate with the Allen-Bradley Kinetix 5500 and 5700 servo-drive platform, using single-cable technology to help optimize a machine’s speed and accuracy.

Rockwell Automation
414-382-2000
www.rockwellautomation.com