Mini case packer

Thanks to Cama’s new mini wraparound case packer, a leading global home and healthcare product manufacturer has managed to transform its packaging processes and infrastructure to be more sustainable. Cama’s expertise was also key in helping the customer overcome several challenges that transpired during the process.

Cardboard folding cartons are a popular packaging choice for brands that are committed to sustainability

There are many reasons why companies look to reinvent their packaging infrastructure and processes, such as the need for increased speed, greater throughput or enhanced flexibility. However, with modern legislation and current consumer sentiments, these days the overriding factor is sustainability.

With single-use plastics broadly shunned worldwide, it is not surprising that many brand owners are transitioning to recyclable materials, with cardboard being one of the most popular choices. Although the move seeks to fulfill a brand owner’s environmental objectives and mandates, it also creates an entirely new set of issues. The company will have to undertake a complete redesign process – from the new materials and concepts for primary product packaging to new machines and plant layout configurations, moving on to the secondary packaging and again the new materials and packaging designs, finally ending at palletising.

This can be a daunting task, even for large multinationals. Yet, theCama Group managed to simplify the entire process for its customer, which manufactures home and healthcare products on a global scale.

RESPONSIBLE CHOICES AND THEIR CHALLENGES

Cama’s customer owns many globally-recognised brands. As an indirect responsibility, the customer must be viewed as taking the lead in sustainability efforts. In many markets its products are packaged in secondary containers, which double as shelf-ready display cases. The problem is these containers often consist of plastic, in the secondary shell/skin and in the trays used to orient the products.

This particular product is a self-administered cold remedy. Interestingly, these packaging and display challenges weren't unique to the cold remedy product as the customer had reported several similar occurrences in its entire healthcare product range. On further investigation, it was determined that the same challenges occur worldwide in countries where there is a home healthcare industry.

The FW746 wraparound case packer from Cama features a compact design and small footprint of just 3500mm

FROM CONCEPT TO COMPLETION

Cama added value to the project from the outset. Alessandro Rocca, the group's sales engineering director, explains: “Firstly, we played a key role in a lengthy design process led by our customer with the aim of creating new secondary packaging and a display concept for the product. We have a highly experienced packaging design team within the group which has helped to create thousands of great packaging ideas over the years. While some were simple and effective, others have been incredibly intricate.”

After a series of tests and deliberations, the new design concept was finalised while taking into consideration the capabilities of packaging machinery.

“The machinery naturally influences all design processes as there are multiple technologies on the market. However, in this instance, a lack of factory real estate meant that only certain machine types and styles could be deployed, which helped define the packaging design,” Rocca adds.

NEW CASE PACKER WITH A SMALLER FOOTPRINT

Other suppliers, who were invited to tender for the project, suggested to-loading packaging machines for the job. But Cama’s new FW746wraparound case packer provided the best solution. Fresh out of the group’s R&D department, the case packer is the latest addition to its class-leading breakthrough generation (BTG) series.

According to Rocca, many of its competitors struggle to combine a high-speed secondary packaging line within a limited space. Meeting speed requirements repeatably and efficiently is no challenge for the group and, with the FW746, this can be done on a machine with a reduced footprint – up to3m smaller than competitor machines.

“The FW746 also benefits from being part of the BTG family, which is setting a new standard in secondary packaging,” he explains. “The modular, scalable and hygienically-designed frameworks house contemporary automation solutions – including advanced rotary and linear servo technology – which can be tightly coupled to robotics developed in-house. This delivers the all-important flexibility and adaptability required by modern packaging operations. The machine range is also based on a digital platform that supports full industry 4.0 capabilities, including AR, VR and virtual testing, training and operation.”

A STEP AHEAD OF MARKET DEMANDS

There were a few twists in the final stages of the project despite the customer's actual packaging procedure being relatively simple.

“We had to flip the products 180°prior to the secondary packaging process. We then devised a very simple concept, which not only delighted the engineers at our customer but also proved to be far more reliable than some of the more complex ideas on the market,” Rocca adds.

Full traceability and checking in place were also required by the customer. This system would need to check, print and verify the carton and its coding before it moved on to the palletizer. Data from the system is collated and shared across a network, which tightly integrates the packaging machine with up-and downstream processes.

“We are fortunate to have a very good relationship with this customer, having successfully delivered packaging solutions to its other factories across the globe,” Rocca comments.

It’s taken years to establish this depth of understanding and trust between the customer and Cama – a relationship which Rocca stresses “is never taken for granted”.

“Whether it’s our first or 100th order, at Cama we put the same amount of effort, dedication and expertise into every job. Although this was a reasonably standard packaging request, we devoted significant resources to the project – including our packaging design team – to ensure the customer was fully satisfied,” he says.

“While it might seem like we were fortunate to have a machine that fitted the application perfectly, it wasn’t down to luck. Cama really studies the market in order to predict customers’ needs. The proactive introduction of the FW746 is just a small part of our strategy to meet modern packaging demands.” •

Cama Group – www.camagroup.com USS Pactech – www.usspactech.co.za