Our yearly feature looking at automation, robotics and vision systems explores the many types – and aspects –of automation from data collection to decontamination
Lorem ipsum dolor sit amet, consectetuer adipiscing elit, sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna
There are new plans to build on the success of this June’s Automation UK and Machine Vision Conference events in Coventry in order to attract even more visitors next time
NEW
Six-axis robots introduced by Epson comply with the latest safety standards while lifting loads of up to 12kg, stretching up to 1.4m and incorporating a unique battery-less encoder Find out more on page 15
INSTALLATIONS
Eight new robot palletising cells are handling brands from Unilever including famous Knorr
Check out the new branding for Automate UK on the website and learn more about the goals of the renamed association www.automate-uk.com
July/August 2024
CKF installs a palletising system in
SYSTEMS
Much has changed in the year since the last feature on this subject in specific sectors such as food and pharmaceuticals and in capabilities from machine learning to robotics able to handle the smallest pieces
REGULAR FEATURES
12 REGULATIONS
52 COMPONENTS
Functional safety is becoming more of a hot topic than ever, given the growing responsibilities of robots and cobots. Employing the services of an external expert can help you pick a way through this regulatory maze, but what criteria do you use when selecting that partner? The list of considerations runs from a proven track record in adhering to deadlines to a good match between your needs and their competencies
ALM, a robot integrator in the north of England, is using safety laser scanners from Sick UK to monitor human proximity to its CoboTend wheeled units, which incorporate a range of Universal Robots arms and can be moved between machine tending roles with safety far simpler to set up
56 MACHINERY FINDER Members’ machinery and services
EDITOR: Paul Gander paul.gander@automate-uk.com
PUBLISHING MANAGER: Bill Lake bill.lake@automate-uk.com
HEAD OF PUBLISHING: David Chadd david.chadd@automate-uk.com
APPLICATIONS FOR FREE COPIES of Machinery Update are considered from speci ers, managers and purchasers of processing and packaging machinery in the UK.
PRINTED BY: John Good Ltd, Progress House, Butlers Leap, Rugby CV21 3RQ Tel: 02476 652800
The Processing and Packaging Machinery Association assumes no responsibility for the statements or opinions, whether attributed or otherwise, in Machinery Update.
This publication is copyright under the Berne convention and the International copyright convention. Apart from any fair dealing for the purposes of research or private study, as permitted under the Copyright, Designs and Patents Act 1988, no part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means in any form without prior written permission of the publishers.
Publishers: PPMA Ltd trading as
KEY FEATURES
• HIGH SENSITIVITY TO ALL METALS
• INTEGRATED CONTROLS for line speed and rejection
• HIGH IMMUNITY to environmental interference
• AUTOMATIC LEARNING & TRACKING of product effect
• DIGITALLY ADJUSTABLE BELT SPEED
• RUGGED AISI 316L stainless steel CONSTRUCTION and food-compatible plastic parts (EU, FDA COMPLIANT)
Automate UK matters
A leading role in all things tech-related
Laurie Barnes CHIEF TECHNICAL OFFICER, AUTOMATE UK (INCORPORATING PPMA, BARA AND UKIVA)
Some of you may have met me – or heard me speak – at the bustling event that was our recent combined Automation UK show and Machine Vision Conference (MVC) and Exhibition in Coventry. If not, then this is an opportunity for me to introduce myself as the new chief technical o cer (CTO) for Automate UK.
This role is central to Automate UK and what it stands for. Over the years, our associations have supported members in many ways. We want to ensure we are technically relevant, too, not just to our members but to the businesses that depend on their systems.
It is about creating and coordinating schemes for machine builders and integrators. It has to be about engaging with standards committees and with other bodies, such as technology catapults and academia. And it is about giving both product manufacturers and members a voice, while bringing them together in more technology-related areas.
Having a clear technical vision will help give Automate UK, its members and downstream manufacturers greater reach and in uence when it comes to crossovers with other industrial sectors.
We would value input on what Automate UK can do to support and deliver training in harder-edged skills
There are two speci c areas where I have already made a start in my rst four months. The rst is to do with standards for vision integration. You may have heard me speak about this at the MVC (see page 7). The second is a reinvigoration of the association’s certi ed robot integrator scheme. Both projects bene t not only the integrators but those who want an objective route to assessing potential suppliers.
Other areas where we would value input include the question of how Automate UK can support and deliver training – not just in ‘so ’ skills, but in harder-edged know-how, too. I know this is a theme of interest both to manufacturers and users of equipment.
To those of you in both of these groups, if you would like me to visit your company to discuss these or other technology-related issues, please contact me at the email below.
Meanwhile, the Coventry shows (reviewed from page 8) demonstrated just how much of an appetite there is for robotics and vision technologies currently across the UK. This issue’s feature (page 24 onwards), explores automation in its widest sense. Our aim – and mine as CTO – is to ensure that all technologies are well-represented and well-supported. E: laurie.barnes@automate-uk.com n
end-of-line packaging with the IMA EOL hub
Partner with IMA END OF LINE for cutting-edge packaging solutions, including robotic manipulation, sleeving, cartoning, shrink wrapping, overwrapping, case packing, palletizing, and labeling
Designed for the food and beverage industry, our bespoke technologies handle any type of product, from cups, pouches, jars, and tubs, to trays, shelf-ready packs, cluster packs, wrap-around cases, and pallets
We provide the packaging you need for display, transport, and storage. Develop your end-of-line packaging with our expertise.
IMA Dairy & Food UK Ltd • ben.todd@ima.it ima.it
Freeze-drying is a key attraction
Liquid pharma range expands capabilities of firm’s new owner
Syntegon has expanded its pharmaceuticals-related business with the acquisition of Azbil Telstar, based in Spain, with its strong portfolio of liquid pharma processing, including freeze-drying. Up to now part of the Japanese Azbil Corporation, Telstar’s range will complement Syntegon’s existing vial filling and isolator technologies, says the new owner. With its headquarters in Barcelona, the business has production in Spain, China and the UK, with engineering and support offices worldwide. It has around 900 employees. As well as freeze-drying, Telstar’s loading and unloading systems will provide a good fit with Syntegon’s current portfolio, says the company.
Vision Integrator Standard gains key supplier support
Automate UK has spearheaded the launch of the UK’s rst Vision Integrator Standard, with chief technical o cer Laurie Barnes joined by integrators and UKIVA members Acrovision and Scorpion Vision at the June MVC event, highlighting the need for –and user bene ts of – this critical benchmark.
“Vision is the keystone of many applications,” said Barnes. “There will be two tiers: Essential, where the necessary processes are in place, though the integrator is not yet certi ed; and Premium, where the company has been audited and has certi cation. This will be an independent place where vision users will be able to nd an integrator they can put their trust in.”
As well as safety, online and on-site audits and assessments will take in essentials such as insurance cover, a ersales
SWEDISH SITE OFFERS PRODUCT TESTING AND MORE Print-and-apply centre opens
Domino Printing Sciences has opened a Print-and-Apply Knowledge Centre in Malmö, Sweden, aiming to support the company’s global customer base across all sectors. “It will provide a space for virtual, and face-to-face, print-and-apply product testing, training and education,” says site director Jan Lindgren. The picture shows Per Henriksson (left) and Mia Lindén of Domino Sweden.
support, quality processes, customer training and track record.
Paul Wilson, managing director of Scorpion Vision, pointed out that he was the founding chair of UKIVA when the standard was rst discussed. “We’ve o en been asked to pick up the pieces of projects that have fallen by the wayside, so we see the standard as being very important,” he told the MVC audience.
“Too many projects go awry
– you do see it happen.”
Acrovision director Paul Cunningham said: “We know we need to positively di erentiate ourselves from our competitors, and we’ve been strong advocates of this initiative within Automation UK and UKIVA.” He emphasised that the standard is not just about the installation itself, but also about wider quality, services and support o ered. Contact: laurie.barnes@ automate-uk.com.
Acquisitions pour Italian drinks equipment firms into one glass
Omnia Technologies, focused on automation and bottling systems for the beverage, dairy and pharmaceutical industries, has acquired Acmi, Sacmi Beverage and Sacmi Labelling. While Acmi had existing o ces in the UK, Sacmi did not. “I very much look forward to serving the UK industry and promoting Sacmi to new and prospective clients –as well as existing ones,” says Omnia UK and Ireland sales director Steve Bradley. “Sales activity is already underway, and we have sold one
Sacmi 27,000 bottles-per-hour labelling machine.”
Omnia was formed in November 2020 as an investment platform bringing together the Della To ola, Bertolaso, TMCI Padovan and other businesses. Equipment brands include Ave Technologies and Z-Italia.
Paul Wilson (left) of Scorpion Vision and Paul Cunningham of Acrovision
Sacmi Beverage joins with the Omnia portfolio
Cabinet-free system gives modular route to pluggable control
Automation UK saw Beckhoff present its MX-System route to automating machines and systems while bypassing the need for conventional control cabinets.
“This is the biggest gamechanger for us in terms of what’s coming,” marketing manager Rachael Duckworth told Machinery Update. “It’s highly applicable to both current and new customers.”
The modular, decentralised system is said to perform all the tasks and exhibit all the features of a classic control cabinet, simplifying the design and reducing the footprint of equipment. It can be installed in around 10% of the time needed for a conventional cabinet, says Beckhoff, with all function modules pluggable into the baseplate.
Automation Forum tackles UK technological skills gap
The UK Automation Forum convened onstage at the Automation UK show to debate the skills gap in UK manufacturing, and possible routes to addressing it.
Alongside host Gail Hunt, the panel consisted of: Rockwell Automation’s Mike Loughran; Chris Rooum and Mike Wilson, both of the Manufacturing Technology Centre (MTC); Oliver Selby of Fanuc UK; and Prof Phil Webb of Cran eld University.
Fanuc’s Selby emphasised that other countries were doing better at passing on key skills. “For example, as a business, we can’t nd enough welders or enough people with a food and drink background to make the business case there,” he said.
Rooum of the MTC suggested that smaller businesses might have the most trouble to attract the right skills. But manufacturers
Smart camera utilises scalable software and evolving features
At the MVC show, alongside Automation UK, Sick demonstrated the power of its new Inspector83x 2D AI smart camera and the NOVA common development so ware platform.
Product manager and architect of the camera Viktor Smedby said: “For applications like quality assurance, detection and sorting tasks, the Inspector83x has yet to meet an application it can’t solve.” New capabilities will be added this year, he said, including colour imaging.
NOVA is scalable and continually evolving, with new tools and features including suppress edge artifacts and AI anomaly detection. The teach-in capability can be used by non-specialists, Sick emphasises.
of all sizes should invest in sta from Day One. “You can use new skills to help recruit as well as to retain sta ,” he said.
Wilson, who alongside his role in automation at the MTC is the Forum chair, stood the ‘skills gap’ idea on its head. “Kids are brought up with technology, and they expect the right technology to attract them to a work environment,” he observed.
“There’s no single silver bullet,” said Rockwell’s
Loughran. “We need more partnerships between companies, schools and universities, so young people know the business, where they might otherwise not have considered it.”
Webb of Cran eld provided a di erent perspective.
“We need people with the skills and knowledge to teach these subjects, too,” he said.
“Restricting access from overseas is blocking these e orts, as well.”
Cloud-based platform for data can keep smart sensors simple
The moneo Cloud platform, on show at Automation UK, is new from ifm and bypasses the need for in-house server management and so ware updates, making data from a range of devices and smart sensors available online.
Marketing manager Jon Morris talked through the example of compressed air metering. “You can monitor pressure, total ow, current ow and temperature all through a single cable,”
he told Machinery Update. In this instance, it can be used to detect leaks, calculate costings and provide insights for preventive maintenance, Morris said.
“A couple of customers have been running it from the prelaunch phase,” he reported.
“But any company can have a dashboard up and running in an a ernoon.”
The UK Automation Forum discussed the skills gap and how it affects industry
MX-System simplifies assembly
The Inspector83X can perform a range of tasks
ifm’s edgeGateway device
New show structure will further develop synergies of co-location
Aer a busy and successful combined Automation UK and Machine Vision Conference (MVC) and exhibition in Coventry in June, plans are already in place to make next year’s show even more of a must-see event.
As Automate UK chief operating o cer Scott McKenna reports, this year’s show was larger and attracted a higher visitor footfall than the previous year.
He sketches out its future trajectory, from the co-located events of the last two years. “From next year, two forces will become one as we create an all-encompassing event,” he says. “Automation UK 2025 will showcase innovations across the wide spectrum of the industrial automation, robotics and vision sector.”
Next year’s event will also take place earlier, on 7 and 8 May 2025.
“Organised by Automate UK and supported by both BARA and UKIVA, two key elements of the association, the recipe is in place to grow this event to be a superpower within the UK’s exhibition sphere,” McKenna adds. “Together we are stronger.”
Details of how the conference programme will be organised are still to be nalised, CEO Peter Williamson explains. “It will also be a smarter exhibition,” he says. “We will be introducing digital innovations at the PPMA Show later this year, and those options will be rolled out to next year’s Automation UK, too.”
A Kawasaki Robot for every application
Kawasaki Robotics
Tel:+44-1925-713-000 www.kawasakirobotics.com/uk/
Automation UK and MVC pack in a host of intelligent technologies
No show should be judged purely on the number of visitors through its doors, and June’s co-located Automation UK and Machine Vision Conference (MVC) and exhibition certainly cleared the ‘quality test’, as well as the numbers benchmark.
At Schmalz UK, sales director Neil Turnbull stressed the visitor interest in customised end e ectors. There had been enquiries, he said, about handling everything from fuel cells and sheet metal to bags of potatoes. “Supported by our own engineers, we can take customers from conceptual design to pre-con guration and con guration trials,” he said, adding that visitors had already opted to take the step into robotics.
Also on the Schmalz stand were compact vacuum pumps, including the ECBPi for heavier loads, able to generate its own vacuum, and the ECBPMi for lighter individual items.
Shown for the rst time by RARUK Automation, Sick’s End-of-Arm Safeguard is a proximity sensor which in this case was integrated as an accessory at the ‘wrist’ of a Universal Robots (UR) arm. Market manager for safety solutions at Sick Martin Kidman explained that,
The Coventry Building Society Arena stayed busy with visitors looking for everything from lenses to complete lines
while it is a separate device, it can be programmed through the UR control system.
On the MVC side of the show, Italy’s Opto Engineering was highlighting the bene ts of special lenses for vision as an alternative, for example, to multi-camera systems. Product manager Beatrice Danese gave a presentation outlining the many di erent lens types and applications on o er. One of the newest systems was the HC range of hypercentric lenses. “These can image the inside of tight containers with narrow openings,” she said. “So it is ideal for the beverage industry, for example.”
Also from Italy, Marco Carboni of Doma Automation explained his work with Shibaura and TM Robotics to design an app to control and monitor the robotics company’s In nifeed pickand-place system. Usable on phones or other handheld devices, the app allows users to create a template for a given application, which could include ne electronics, pharmaceutical or medical
operations. “What’s especially important is to provide a push noti cation on the app if there’s an issue,” he said.
For vacuum specialist SMC, the ‘show-stopper’, according to product specialist Connor Bing, was the company’s Air Management System. “This can continuously log or monitor air use in any given machine, and will either drop the pressure or isolate it altogether when it’s not being used,” he told Machinery Update.
Vacuum grippers with no requirement for an air source included the ZXPE5, which SMC saw as being ideal for mobile robotics or
for those parts of the factory where there is no vacuum supply. Also on show was the CRP Series compact compressor. “This can act as a vacuum pump or for positive displacement, the choice is yours,” said Bing.
Machine access and guarding specialist IDEM Safety showed its latestgeneration network safety switch which, said sales director Tony Baggott, can replace up to four eld devices and can be con gured over either CIP Safety or PROFIsafe. Other safety functions such as light curtains can be connected to the same unit, he explained.
Piab shared its stand with a UR20 robot running palletising so ware from customer WMH and utilising Piab tooling. The cobot, which can li up to 20kg, had an especially compact footprint. Regarding its own end e ectors, Piab said it was looking at many new applications including car batteries, where antistatic properties in the vacuum cups were particularly important.
The ECBPi intelligent vacuum pump
TM Robotics showed the Infinifeed
IRegulations
A route through the functional safety maze
Stewart Robinson
Paul Laidler
BUSINESS DIRECTOR FOR MACHINERY SAFTEY AT TÜV SÜD PRODUCT SERVICE
PRINCIPAL ENGINEER AND FUNCTIONAL SAFETY EXPERT AT TÜV SÜD
Finding the right testing, inspection and certification partner can be a huge help in navigating the complexities of functional safety standards and regulation – but which one is best for you?
n the machine industry, the signi cance of functional safety has increased continuously as a result of advancing automation. With the increasing connectivity of systems and plants, plus the growing possibilities of remote control, damage events have become more likely and safety-related parts of control systems more complex. One example is the introduction of collaborative operation with robots, where people and machines work more closely together.
Functional safety is therefore increasingly important, with standards covering the safety-related parts of control systems within a machine. For example, ISO 13849 applies to parts of machinery control systems that are assigned to providing safety functions. It provides safety requirements and guidance on the principles of design, and the integration of safety-related parts of control systems, both hardware and so ware.
PRIORITISING SAFETY
Ultimately it is organisations and people that are responsible for realising functionally safe products and systems. While the focus of interest has always been the safety of operating and maintenance sta , the other goal is to minimise the costs of operation and servicing or maintenance. E ective functional safety management is therefore vital.
This includes the de nition of the roles and tasks of the individuals involved, proof of their competence, and the quali cation measures necessary to ensure up-to-date knowledge in this sector. However, the wide range of functional safety standards creates a complex regulatory landscape, sometimes making it di cult to nd the appropriate product or systemrelated standard. It therefore o en makes sense to get external expert help, but what aspects should you evaluate when making this important decision about where to source support?
You will want to select a functional safety provider with experience and expertise in your product or industry. This is particularly important if you are looking for a provider that can o er solutions to problems in real-time. Ideally, there will be a mix of experienced engineers and technicians, innovative, cutting-edge technology, and professional project managers who work together to achieve the best possible results for your project.
It may sound obvious, but it is imperative to nd out whether the functional safety
Confirm what activities are included in each service to ensure both parties are on the same page
Quality, undoubtably, should be one of the key aspects to consider when comparing certi cation providers. Working with an organisation that has an established and transparent culture of quality, where processes are constantly reviewed and improved, and which continuously strives to be the best, will provide you with a foundation for success. Find out about the organisation’s track record – a consistent string of successful projects is a good indication that future projects will be successful too. You may also want to look online for the certi er’s current certi cates.
certifying organisation will be able to provide you with all the services you need for your product development programme. What is critical here is not to accept things at face value.
Con rm what activities are included in each service to ensure both parties are on the same page. Also, you might like to consider whether all activities and services are provided directly by the provider’s employees, or via sub-contractors. Having all the testing and certi cation services ‘under one roof’ has the signi cant advantage of helping reduce timelines by ensuring technical rigour and
enabling more e cient project management.
Moving beyond the more technical criteria, communication is a crucial factor when selecting a testing and certi cation provider. A healthy relationship between the client and provider is pivotal for the successful completion of your functional safety testing program to time and budget.
DELIVERING ON TIME
When evaluating functional safety testing and certi cation providers for their ability to deliver against timelines, look for documented evidence of meeting milestones and project completion. If you are considering an integrated product approach with one organisation, look to evaluate the experience and expertise of the project manager who will run your programme, as their role will be pivotal. Ideally, the TIC (testing, inspection, certi cation) organisation should be able to provide real-life examples and case studies of successful programmes they have completed.
It is clear that a holistic approach to functional safety is therefore required, which necessitates expertise in various application elds and all project phases, from design to decommissioning.
i For more information contact W www.tuvsud.com
TÜV SÜD Product Service is Automate UK’s technical and legislative partner
With Murrelektronik‘s Vision Installation Solutions, you can get started with industrial image processing and immediately benefit from the advantages with little effort, guaranteeing a quick return on investment.
Plug and Play for industrial image processing
New Machinery
Performance improves for end-of-line system
The latest case and tray-packing machine from German manufacturer Somic groups together individual stations on a linear footprint, while building in improved ergonomics, access and ease of changeover.
On the 434 machine series, servo-driven format adjustments can be made automatically from the operator panel when it comes to folding tools, gluing positions and the blank magazine, for example. Only a few manual changes are required using the Somic QuickChange System. Compared with previous generations of machine, the company estimates this automation can yield time savings on format changeover of up to 70%.
Thickness gauge has role to play on metal sheet and film lines
Given the trend towards product variants and shorter runs, it is hard to overstate the importance of these e ciency gains, says Somic.
Access improvements include the adoption of frame-high doors which open fully to 180 degrees, ush with the frame, facilitating movement around the machine. The company talks about the new machine o ering “perfect conditions” and “unimpeded access” for operators. Machine status is now even clearer, thanks to the integration of LED lights into the corner columns.
Collation and grouping stations are docked on to the side of the machine in a separate frame concept,
says Somic. This modular element makes it easier to subsequently change the machine, should the handling of di erent product ranges or formats be required.
Smaller details are also signi cant, the company adds, pointing to the example of the glue- lling unit, where granules of hot-melt adhesive can be readily loaded from the outside of the machine.
Somic is represented and supported in the UK by Alpma GB.
T 01256 467177
W www.alpma.co.uk
The latest C-frame inline thickness measurement system from Micro-Epsilon offers sensing accuracy of +/- 0.25µm and fills a gap in the market, says the company, between basic sensors and dedicated, high-performance systems. For use in either inline or offline settings, the thicknessGAUGE is available in several versions using one of three sensor types: laser triangulation; laser profile; or confocal chromatic sensing. This means that the best system can be specified to suit the material and surface type – including metal, plastics and wood – as well as the performance requirement.
Measuring widths up to 600mm are now available for all C-frame systems. 0151 355 6070
T
W www.micro-epsilon.co.uk
Containment version of tablet press integrates all essential requirements for GMP compliance and for ease of cleaning
The centrepiece of Romaco’s exhibit at this year’s ACHEMA show in Germany was the new containment version of its Kilian KTP 420X C rotary tablet press.
According to the company, the press ful ls all requirements for processing active pharmaceutical ingredients up to OEB Level 3 with medium toxicological potency. This includes numerous classes of medication, for example those for treating hypertension, ventricular
Doors feature electric locking
ulcers or bronchial asthma. Integral to the unit is the Restricted Access Barrier
System (RABS), featuring glove ports to protect the operator as well as a Rapid Transfer Port (RTP) for contamination-free materials transfer.
Features ensuring GMP compliance include: negative pressure in the compaction area; electric door locks; dust-tight docking systems; and a dust-tight tablet chute. Among speci c elements of hygienic design is the hermetic separation between the compaction and technical
areas to prevent tablet dust from entering the mechanical compartment, says Romaco. The compaction area is designed as a deepdrawn, single-piece run-o containment incorporating polished surfaces and large radii for ease of cleaning. The overall design means that protective clothing is only required while cleaning the press and not during production.
T 01252 444334
W www.pharmamachinery.co.uk
The German manufacturer says the machine offers unimpeded access to operators
Aiming for a gap in the market
Six-axis robot range will meet toughest standards
Epson has launched a range of six-axis SCARA robots with new controller and safety functions in order to comply with the latest standards certi ed by TÜV SÜD, with ve di erent variants o ered in the range.
Building on the success of its C series robots, Epson says that the new Cx-B series is its rst six-axis range to comply with these current standards, and comes with the latest generation of controller, battery-less encoder and a variety of mounting options.
The ve models span payloads of between 4kg and 12kg and arm lengths of between 600mm and 1,400mm.
The robots are designed to operate safely around humans
“Not only does [the range] conform to the latest high safety standards but it also includes a unique battery-less encoder that means far less intervention, maintenance and operational downtime,”
says head of manufacturing solutions at Epson Europe
Volker Spanier.
Described as “slimline”, the range is designed for areas where space is tight.
Design also focused on the need to perform rapid, precise work in safe proximity to humans. It is said to be ideal for high-speed and potentially
CONVEYORS
sophisticated applications including palletising or machine tending in a cross-section of industries.
The new RC-700E controller is said to facilitate easy-to-con gure safety functions. This allows the machine to maintain safe robot motion while operators perform their tasks in close proximity to it. The series comes with Epson’s standard RC+ or RC+ Express robot installation so ware.
All functions are tested, documented, validated and certi ed by TÜV SÜD. The series meets the latest machinery directives and harmonised industrial robot standard.
T 0871 423 7766
W www.epson.eu
New representation for folding systems across mainland UK
Friedheim International is now supplying the GUK range of specialist folding machines in mainland UK, along with spare parts, support and service.
Describing the GUK range as “complex, next-generation, high-capacity folding machines”, Friedheim points out that the equipment is developed and produced in-house at the company’s headquarters in Wellendingen, Germany. More than 100 machine variants are available and are widely used in the packaging and pharmaceuticals industries, as well as printing and other sectors. Originally founded as a family company in 1948, GUK has grown to the point where it now has 200 employees and 14 construction lines specialising in folding and turning parts technology.
T
01442 206100
W www.friedheimpackaging.co.uk
The GUK showroom in Germany
New Machinery
Labeller brings together wraparound and coding
Herma has combined a wraparound system for lm labels on pharmaceutical containers with a laser coder to lay down what are e ectively indelible codes and variable data.
The 132M HC labelling machine was shown at the ACHEMA show in Germany and features a U510 UV laser from Domino. The line will code and apply labels at up to 600 products per minute, says head of the labelling machines division Martin Kühl.
“Together with the new Herma UV lm labels, this represents the rst step into a new labelling era,” he says.
The advantages of laser, says Herma, are that it involves no consumables, is contactless and hence very low-maintenance, simply changing the colour of the lm substrate. Importantly in a pharmaceutical setting, labels with missing or illegible print or code are automatically rejected before the application stage, and only veri ed labels are applied.
If a label is rejected, the starwheel automatically stops brie y to ensure every product has a label, and UV sensors check for label presence on each container. Unlabelled containers are also rejected before the outfeed, but in a careful and gentle manner, says Herma.
The implementation of Clean Design concepts means that the starwheel is larger than on previous models, and this allows for the
introduction of additional checking, says the company, should it be required –for instance, of a 2D code on the cap.
Integrating a human machine interface (HMI) based on “clear and intuitive” controls and symbols, the 132M HC will handle container diameters between 14.75mm and 110mm.
T 01440 763366
W www.hermalabellingmachines.co.uk
Cushioning options fill up the void with paper and plastics
SEE has added to its Sealed Air brand ProPad paper cushioning with the introduction of the ProPad Coiler, at the same time extending its options for Bubble Wrap.
Made from only recycled paper, and designed with kerbside recycling in mind, the ProPad base material is said to be a robust alternative to film and foam cushioning. High density coils can be quickly produced on the machine, says marketing director Oliver Kammler.
“Businesses have sometimes had to choose between product protection and packaging sustainability,” he points out, citing the automotive and engineering sectors as examples.
Meanwhile, the Bubble Wrap Inflator will produce this branded plastics cushioning at speeds of up to 24m per minute.
T
01480 224000
W www.sealedair.com
Roll handling with spindle attachment comes with side-shift mechanism to tackle restricted packaging machinery access
Originally developed in response to the needs of a pharmaceutical industry customer, roll handling incorporating a twin spindle attachment and side-shi facility is now available from Packline.
The customer in question needed to manoeuvre rolls of packaging materials precisely into place for loading onto line equipment, even where space was at a premium.
Packline says the side-shi mechanism o ers a simple
means of positioning
the roll exactly where it is required, and is available as a manual or electronic
system. A stabilised carriage device reduces unnecessary movement, it adds, keeping the load securely in line.
While the roll is still on the twin spindle, rotating arms mean that it can be unwound in situ for splicing on to the packaging machine. Two levers on the spindles enable the operator to rotate the attachment arms as required while keeping them locked in place during transportation.
Part of the Compac range of li ers, the unit features
straddle legs to allow access even over the top of a pallet. The stainless steel construction makes it compatible with hygienic and clean-room applications, says Packline. Top li capacity is 200kg.
The company o ers a design service in order to tailor equipment to a customer’s speci c needs, and points out that its range of attachments are interchangeable using a quick release system.
T 01202 307700
W www.packline.co.uk
The system lifts up to 200kg
SEE’s ProPad Coiler in action
Labels with no code are not applied and unlabelled containers are rejected
Vial-packaging design makes any product mix-ups much less likely
With a stand of its own at the ACHEMA show in June, SchubertPharma introduced a new vial-packaging machine, where line clearance –the ability to demonstrate a clear break between one product batch and the next –is the priority.
The top-loading system has a table-top design which di erentiates it from other Schubert-Pharma open top-loaders, making it even easier for pharmaceuticals companies to guarantee the required line clearance, says group manager for pharma product management Klaus Dierolf.
Up to 10 vials can go into each carton
“Line clearance basically means ensuring a streamlined, orderly work area to prevent product mix-ups,” he explains.
“Pharmaceutical technicians have to carry out a line clearance a er packaging a batch to ensure that all products have been removed from the machine before a new batch is started. This innovation prevents mixing.”
In theory, at least, SchubertPharma’s existing top-loading design could allow product to nd its way into the base of the machine during the packaging process. The new table-top pro le avoids this eventuality.
One, three, ve or 10 vials can be packed into each carton, with an F2 robot performing the pick-and-place.
T 01676 525825
W www.schubert.group/en/ pharma.html
A one-stop solution for all futureoriented packaging concepts
SOMIC has created a one-stop solution for all future-oriented packaging concepts with the new 434 series. It has been cleverly engineered to cater for tray packaging, tray-cover or wraparound solutions. Based on
proven, tested and standardised function groups, it offers maximum performance on a compact footprint.
For more information call 01256 467177 or visit somic-packaging.co.uk
Telephone: 01256 467177
Email: sales@alpma.co.uk www.alpma.co.uk
Installation News
Palletising robot allows for fast installation and future upgrades
CKF has added a robot palletising system to a UK plant belonging to European food group Vandemoortele, with speed and ease of installation a key bene t for the customer.
Based on a Yaskawa PL80 robot and CKF’s 24 Vdc CRC case conveyor system, what the supplier calls its standard robotic palletising cell has been installed at the food company’s Worcester factory.
Spokesperson for Vandemoortele Gareth Manton says the cell has allowed the plant to increase throughput and streamline its operations.
“The installation was quick, smooth and to an extremely high standard,” he adds.
“Our investment will serve us for many years, as this solution can easily be repurposed if we decide to upgrade or change our operations. It has allowed us to remove repetitive manual handling and reallocate valuable personnel to more interesting tasks.”
The robotic palletising cell incorporates a decline belt and accumulation area
The customer is currently using the palletiser on its pastry products line, where it handles a throughput of 20 cases per minute. Cases vary in size and weight.
The plinth system used by CKF means that the cell can be mechanically located and installed, by being tied back to the main system structure, with minimal interruption to production.
At the core of the installation, Yaskawa Pallet Solver so ware is said to allow for fast commissioning and exibility in introducing new pallet patterns, with minimal training requirements.
Operators familiar with, and with access to, the system will be able to create new pallet patterns on the humanmachine interface (HMI) screen.
The robot uses a single-zone
vacuum gripper which will allow the packing and placing of single cases, but also multiple cases, robust bags or ow-wraps.
As the customer makes clear, the system is designed to be easy to relocate and repurpose, with a variety of potential future handling options in mind.
From the production oor above, cases are fed via a decline belt and spiral conveyors manufactured and installed by CKF. Once at the palletising level, cases are handled by another CKF system, the 24Vdc CRC conveyor. This allows for the option of manual feed, as well as incorporating an ebb-and- ow bu er zeropressure accumulation area for use when pallets are being indexed in and out.
A er the bu ering area, cases are then fed into the palletiser along with cases coming straight down the decline belt from production.
T 01452 728753
W www.ckf.co.uk
Breakfast cereal manufacturer uses side-seal shrink-wrap line to produce larger collations and double its throughput
A well-known UK producer of breakfast cereals has doubled throughput on its shrink-wrapping operation for multipacks, while also allowing wider pack sizes, by installing a new side-seal line and double-chamber shrink tunnel, both sourced from Yorkshire Packaging Systems (YPS) .
The 800mm-wide Minipack Pratika 80-T MPS side sealer will handle multipacks up to 320mm high and of unrestricted length.
The previous line was limited to handling packs up to 200mm high and 500mm in length. As YPS notes, this helps to future-proof the line for
new product adaptations, while also halving labour requirements.
Over 250 customisable programmes can be saved on the user interface.
“YPS supported our team throughout the trials, commissioning and initial production, including returning for extra training and support the following week,” says the customer’s operations manager.
Line speeds are now 14 or 15 packs per minute (ppm),
compared with previous speeds of up to 8ppm. By replacing a singlechamber shrink tunnel with a double chamber has helped increase processing speeds, says YPS, but also improved pack appearance, since the lm is shrunk at a lower temperature. This also means that shrink lms with 30% or more recycled content can be used, with the option of reducing lm thickness, too.
T 01484 715111
W www.yps.co.uk
Wrapping speed has been boosted
Cell for aseptic filling of high-value drugs goes to US contract producer
In the rst US installation of Syntegon’s Versynta microBatch cell for small batch production of highpotency and o en high-value drugs, contract manufacturer Kindeva is using the system to ll syringes, cartridges and vials with virtually no product loss. As a provider of aseptic ll- nish contract development and manufacturing, Kindeva will be using the production cell to ll between 120 and 500 syringes or containers per hour with pharmaceuticals in areas such as cell and gene therapy. Fast batch-to-batch changeovers are a priority for the company.
Operator intervention is minimised Kindeva global chief commercial o cer David Stevens underlines both the supplier’s technical expertise and its ability to work as a partner. “Syntegon’s Versynta microBatch enables Kindeva to o er signi cant exibility to our customers by rapidly adding clinical development and small-scale commercial GMP lling capacity, which complements our large-scale vial, syringe and cartridge isolator lling lines,” he says. Syntegon says it developed the system with the new EU GMP Annex 1 in mind. This is setting new benchmarks, it says, in aseptic operations. T 01332 626262
W www.syntegon.com
Intralogistics – fully automated flexibility
Streamlined routing and processes combined with agile material flows that can be flexibly matched to changing production and dispatch requirements: System Logistics is the Krones Group’s expert team for innovative, fully automated solutions geared to optimising your intralogistics, warehousing and material-flow technology.
Unilever’s Ploiesti plant in Romania has installed a palletising area of no fewer than eight robotic cells, supplied by Sidel, fed from 28 lines packing dry meal and sauce bases, including the well-known Knorr brand.
Products arrive in a variety of primary packaging and multipacks, including pouches, bags and cartons, and end up inside an equally wide array of secondary and tertiary packs, from American cases to tray-andhood combinations, tray-and shrink lm and shelf-ready options.
Plant volumes have tripled from 12,000 tonnes to 35,000 tonnes per annum, while the number of stockkeeping units (SKUs) has
The eight robotic cells from Sidel will palletise nearly 100 pallets every hour grown from 200 to 1,000, says Unilever. The number of packaging lines has doubled to the current 28, while personnel have increased from 200 to 700.
The eight robotic cells require “several hundred
metres” of case and pallet conveyors, four pallet handling shuttles and two stretch-wrappers, hitting a production rate of 98 pallets an hour. The cells are in two separate clusters, one of ve robots and one of three.
Each cluster has one central magazine for all pallet types and sizes, one induction shuttle for full pallet discharge and one compact shuttle for empty pallet delivery. Each cell has three or four product infeeds, and Sidel says the robot utilisation rate stands at 92%.
Technical manager at Unilever, Laurentiu Badulescu agrees this was a complex project. “However, the solution developed by Sidel is based on standard, proven modules, which have been developed and implemented in other projects,” he says, adding that they have been combined in a smart and customised way for Ploiesti.
T 01707 292820
W www.sidel.com
Stainless Steel Cable Management Systems
Keg washing and racking benefits German brewer
Hell Brauerei in Bavaria, a cra brewer which is gradually automating its processes, has acquired the rst KHS Innokeg X washing and racking – or lling – system for kegs, bene tting from the all-in-one operation said to be ideal for smaller outputs.
With 20% of the brewer’s beer lled into barrels and the remaining 80% into glass, moving to an e cient system for reusable kegs was essential, as brewery manager Georg Hell explains.
“We had to have the barrels washed in a neighbouring brewer before we then racked them by hand,” he says. “This took a lot of time.”
The system can process up to 25 reusable kegs of up to 58 litres every hour. Hell is particularly enthusiastic about the processing head’s ability to carry out
multiple tasks in sequence.
“This is a huge advantage,” he says. “With comparable systems on the market, you have to move the barrel to a second station and then position it.”
Once the barrel is in place, the process starts automatically. “All steps in the process from emptying to prewashing to washing with hot caustic and racking, are perfectly co-ordinated with one another,” he adds.
Importantly, the unit is also extremely space-e cient, taking up the oor area of a single euro pallet – or around 1.8m2
Semi-automatic systems with separate washing and racking stations typically occupy more space.
T 0121 713 6900
W www.khs.com
Mixer allows bakery to lift quality and output even with heavier cake doughs
Scottish bakery Mathiesons has acquired a new VMI mixer from European Process Plant (EPP) to replace a 12-year-old vessel that had reached the end of its life, the aim being to raise quality and output levels in supplying major UK retailers.
“It was time for a replacement, as the so ware was becoming outdated and parts were hard to source,” explains Mathiesons managing director Nick Wills.
When the company, which is famous for its stollen and chilled bakery cakes, approached EPP, the equipment supplier recommended VMI’s SPI 400AV mixer.
T 01372 745558
W www.eppltd.co.uk
All keg operations take place at a single station
Installation News
Machine vision enables bakery to reduce errors
Zebra Technologies reports that an industrial bakery business has reduced error rates and increased throughput thanks to a machine vision system which uses Zebra’s Aurora Design Assistant so ware.
As well as being able to inspect its full range of breads using a single machine vision system, the bakery can carry out e cient, automated robot picking of up to 30 packs per minute without damaging either the bread or the packaging, says Zebra. Compared with ‘traditional’ camera and lighting inspection approaches, the supplier estimates the bakery has made a 75% cost saving.
The customer originally approached KINE, a Finlandbased turnkey robotics supplier, which worked together with OEM Finland to replace an ine cient manual operation at the plant. OEM Finland is a Zebra-registered industrial system integrator and advanced machine vision specialisation partner.
Previously, bagged loaves and rolls had been manually positioned on – and removed from – the line, but mistakes were made partly due to the variability in product size and shape. The type of optical sensor used also had di cultly detecting defects due to the low contrast levels and re ectivity of the lm packaging.
“We decided to leverage Zebra’s Aurora Design Assistant machine vision so ware for its versatile, powerful capabilities that provide the robustness and integration needed to visually inspect the variations in packaged bread,” says chief technology o cer at KINE Kimmo Salonen.
The new system consists of a PLC, robotic grip, 3D time-of- ight camera and Aurora Design Assistant so ware. The so ware is said to have eliminated the need for multiple cameras and lighting, while reducing problems with contrast and re ection.
T 01628 956900
W www.zebra.com
Supplier reaches its 400th bagging line filling fresh produce
GIC recently sold its 400th vertical form-fill-seal (VFFS) machine into the fresh produce sector, now installed at Vale Royal Fresh Foods in Cheshire, where it is bagging beansprouts. GIC, based in Gainsborough, forged a relationship with Vale Royal at the 2014 PPMA Show. The company first acquired a GIC4100 machine in 2016, followed by a second – and now a third.
Vale Royal managing director Cynthia Lam praises both the supplier’s workmanship and friendly, ‘small-business’ approach. “They share their expertise and knowledge to ensure I have the right equipment for my business needs,” she says, pointing out that the sales team, too, started out as engineers. 01427 611885
T
W www.gic.uk.net
Portuguese cheese specialist reaps rewards from skin film and board carrier packaging produced on traysealing line
Portuguese cheese specialist Queijos Santiago is using a Sealpac A6 traysealer to produce barrier lm FlatSkin packs for its small regional cheeses against a board carrier, brightly branded for retail –including for the travel trade.
“The special FlatSkin solution preserves the aroma and sensory properties of the cheese, hence extending its shelf-life,” says chief executive of the dairy João Santiago. “In addition, the packaging is a true eye-catcher.”
Three di erent types of cheese weighing 100g are placed on each carrier before the lm is sealed in place. The company now also uses the system for its cheese wedges. “Due to the tight skin lm, it even seems as if there is no plastic round the product at all,” says Santiago.
The company originally sourced an A4 traysealer from EMO, Sealpac’s exclusive distributor in Spain and Portugal, for a year-long trial period, in the process
becoming the rst dairy company to use FlatSkin on its products. But retail demand was so strong that a er only four months, the cheese producer switched to the higher-capacity A6 machine.
The FlatSkin board carrier is laminated with a removable polymer layer, while the top skin pack layer has a peel tab. Queijos Santiago’s Portalegre site, east of Lisbon, was opened in 2022.
T 0845 302 3056
W www.sealpac-uk.com
Cheeses being prepared for packing
Vale Royal values GIC’s approach
Zebra’s Aurora Design Assistant transforms the line
Feature: Automation, robotics and vision: intro
The UK has some catching up to do in utilising robots
Collaborative robots may represent just one slice of a much larger robot market, but insights here can provide a useful perspective on that wider sector, and arguably on automation as a whole.
On this basis, there were mixed messages from Interact Analysis’ report The Collaborative Robot Market – 2024. On the one hand, it registered growth in the international cobot market which burst through the $1 billion ceiling for the rst time, reaching a value of $1.07bn in 2023.
Then again, the data company’s assessment is that the growth rate hit a new low-point for the period since the pandemic. An increase of 11.9% might sound robust for most sectors, but this compares with a heady upswing of over 35% internationally in 2021, for instance. More positively, Interact Analysis forecasts a near doubling of the growth rate for cobot sales to 22% in 2024, at which point it predicts that the rate will plateau. When it comes to machine vision, the same company believes the UK speci cally will see more modest growth than for cobots, but will outperform global averages. For the period to 2028, the data provider cites compound annual growth (CAGR) of 7.6%, ahead of the global average of 6.4% - but still well below forecast European growth of 28.4%.
EUROPEAN COMPARISONS
That comparison with the rest of Europe remains un attering for robotics more generally. Fanuc UK points out that, at 25th in the global robotics league table, the UK is the only G7 country to sit outside the top 20. The UK’s 98 robots per 10,000 workers pales in comparison with Germany’s 415.
Vice president of Fanuc Europe Dr Bob Struijk draws a few informative contrasts between the UK and Germany in this respect.
Automation in the ascendant
“In Germany, collaborative e orts between industry and academia contribute to a continuous cycle of research, development and implementation,” he says, pointing out that this creates an ecosystem driven by technological progress. He believes the role of government is similarly critical. “The penetration of robotics and automation in the UK is especially low among small and mediumsized enterprises (SMEs),” he observes. “Government tax breaks or accelerated depreciation of robots could certainly help to change this.”
ALS Mechatronic, which supplies equipment in areas including automatic bagging and conveying of milk polybottles, underlines the bene ts of automation and robotics in these and other food and drink categories.
Executive director Laura Steward
says there were in fact incentives for automation included in the last budget, also supported by Labour. “The British Government thankfully has woken up to the potential, and recognises the urgent need to make automation more accessible and a ordable to SMEs, if productivity growth is to soar,” she says.
Speci cally, a ‘full expensing’ clause o ers 100% rst-year corporation tax relief to companies on qualifying new main-rate plant and machinery investments. There is also a 50% rst-year allowance for expenditure by companies on new special-rate (including longlife) assets. Both these provisions run up to the end of March 2026. In addition, the Annual Investment Allowance provides rst-year relief for plant and machinery investments up to £1 million, ALS Mechatronic points out. n
A new installation of Fanuc robotics at salad dressing specialist Brunos in Switzerland is palletising bottles
A CONFECTIONERY JUNGLE PACKAGED AUTOMATICALLY. BROUGHT TO LIFE WITH SCHUBERT.
How can you package confectionery and baked goods flexibly in a wide variety of pack formats? With pick & place robots that accurately position each product and systems that effortlessly switch between different packaging materials. Saving precious resources –with virtually no waste. This is our Mission Blue. A true benefit for the climate and the many FMCG manufacturers who have been relying on us since 1966. And for you too. www.schubert.group/en/confectionery-snacks.html
Striking a balance in standard design
Automating pharmaceutical and medical processes is so product-dependent, how does standardisation t?
In the world of medical devices, manual packing processes remain surprisingly common, given the high value of products and o en small batch sizes. But as this sector, like others, moves towards a reduced reliance on human operators, questions about how to balance cost-e cient standardisation in machinery design and product-speci c customisation are more urgent than ever.
No standard cartoner could match the intricate packing process performed manually for products such as surgical implants or bone screws, typically produced in batches of just 50-to-100 units. Developing completely new
equipment would, on the other hand, be extremely expensive, time-consuming – and risky, argues German machine manufacturer Christ Packing Systems, represented in the UK by S3 Process.
“Medical device companies need a tailor-made solution that meets their high
quality standards and ts their internal cost and time schedules,” says key account manager at Christ, Jürgen Sikora, pointing to the company’s BoxTeq cartoner as a prime example of modular design, allowing extensive customisation while maintaining a standardised core.
The BoxTeq cartoner in operation
the packaging and labelling process. “A camera and sensor solution were also integrated to ensure reliable quality control.”
“Using vertical integration of approximately 87% gives us the exibility to implement customer-speci c adaptations quickly and easily,” he says. For the implants, product speci cs were built in to
A special container was designed to feed the hard blisters, containing the surgical implants, into the cartoner. The patient lea et is automatically printed, folded and added to the blister, with labels also being applied to the folding carton, all of this being monitored by cameras and sensors for accuracy.
The customer requested a quick-changeover capability.
“Instead of the product carriers being coupled with only one drive, they were equipped with two independent drives,” says Sikora. “This enables
MAGIC GRIPPERS:
VMECA’s Magic Grippers can be zoned and adapted to meet the vision requirements of any system. They can be utilised throughout the automated process for countless applications. A unique product that simplifies and economises an end of arm tool (EOAT) solution to exact requirements. Simmatic will tailor and design a gripper specific to your project’s demands.
The Ceia PH210 is designed to increase uptime
automatic longitudinal adjustment of the bucket train transport.”
A decision to shi from optional to standard features will always be easier where the change is not productspeci c and represents a bene t for all potential users. This is the rationale behind Italian equipment manufacturer Ceia’s launch of the PH210 metal detector, designed for pharmaceutical and nutraceutical markets.
FULLY DIGITAL DESIGN
In an advance on previous systems, the key innovation with the PH210 is the embedded network controller and data logger PC. This was formerly an option, but now comes as standard. The fully digital electronic design incorporates multi-point autolearn, auto-test and automatic quality control functions. All of this will increase productivity and save on downtime, says Ceia’s UK and Ireland partner MDS.
The PH210 is also the rst Ceia metal detector to have a separate captive touchscreen, designed for simplicity with an easy-to-use operator interface.
The Italian company’s sales manager for pharmaceutical and metal detection systems Massimo Meacci, explains that the launch at ACHEMA, Germany, in June was extremely positive. “The new design and touchscreen were really well received, and the
improvement that we can give in the level of detection is something that has really hit home with many customers,” he says.
David Hale, sales director at MDS, reports that the PH210 will see its UK launch at the PPMA Show in September.
“We will have the new
technology available for product testing, evaluation and demonstrations,” he says.
W www.mds.org.uk
W www.s3process.co.uk
Technology inspired by human talent
cama-UK@camagroup.com
The new product VisioPointer® is one of ree new Vision Inspection products from Minebea Intec and fur er enhances e already popular inspection portfolio. It is also one of e key products at helps drive automation wi in food production and manufacturing. Combined wi e Automatic Weigh Price Labeller WPL-A customers can automate eir entire end of production line where labelling plays a significant part of e manufacturing.
The new product VisioPointer® is one of ree new Vision Inspection products from Minebea Intec and fur er enhances e already popular inspection portfolio. It is also one of e key products at helps drive automation wi in food production and manufacturing. Combined wi e Automatic Weigh Price Labeller WPL-A customers can automate eir entire end of production line where labelling plays a significant part of e manufacturing.
Feature: Automation, robotics and vision
It takes more than robotic arms to do the heaviest li ing
While the strength, agility and accuracy of the articulated arm will always be the focus for any palletising, handling or other type of automated installation, its e ectiveness will depend on how it is supported – literally and guratively – at the two ends of that arm.
Kyrus chose the Automation UK 2024 exhibition in Coventry as the occasion on which to launch the latest version of its modular seventh-axis track range. The Mini, Midi and Max systems are fully modular, says the company, creating cost-e ective tracks with fully-customisable lengths and strokes. They are engineered using an aluminium extrusion system which, it adds, allows for the linear movement of dynamic and static payloads up to 3,000kg.
COST-EFFECTIVE MOBILITY
“Extending the reach of your robot is key to maximising its productivity and e ciency,” says managing director David Samuel. “As more and more companies embrace automation to improve process productivity, it is essential that a cost-e ective solution exists for giving your robot ‘extra legs’ that it can use to do more work.”
The track can accommodate a range of drive options, including: helical rack-and-pinion, belt drive, caterpillar belt drive, ball screw and pneumatic. This means that the spread of potential
Support act to the robot stars
The proprietary aluminium extrusion system is tted to a heavy-duty steel support structure to deliver all the necessary rigidity and robustness, which in turn allows for high accuracy and positional repeatability, says Kyrus.
Modular track sections are up to 5m in length, with standard modules in 5m, 2.5m and 1.25m lengths, capable of being joined to give a stroke of any length.
Customised dimensions are also available.
All tracks are supplied with a low-backlash planetary gearbox, mechanically matched to the servo motor speci ed. This means the seventh axis can be easily integrated either with robot auxiliary axis motors or an entirely separate control system, says Kyrus.
At the opposite extremity of the robot arm, Piab o ers a di erent kind of support – but one that is equally essential. Its piCOBOT series of vacuum grippers can, like the Kyrus track range, cover most customer requirements.
Those customers have included DCL Logistics, which specialises in e-commerce and wider logistics.
Here, integrated into a cobot, the piCOBOT end e ector is said to ensure precise and e cient handling of a wide range of items, streamlining work ow, reducing manual labour and achieving greater accuracy in the order ful lment process.
For heavier loads, the piCOBOT L has also seen applications in logistics, as well as various types of manufacturing. This can be combined with the intelligent features of the piCOMPACT 23 platform, says the company, and is allowing manufacturers to increase throughput at the palletising stage, reducing the challenges and risks associated with the manual handling of large loads.
Piab is also addressing the needs of users which, for whatever reason, cannot access compressed air at the cobot’s working location. The piCOBOT Electric is, as the name suggests, an all-electric version of the gripper system, and can be used, for instance, in warehouses where cobots are required to perform a pick-andplace function.
The seventh-axis track range from Kyrus is modular, with aluminium extrusion used for extra strength
range
in
Keep the line and the timeline tight
Line e
ciency?
Of course, but how time-e ciently is that goal going to be reached, and what will delay it?
By the time the decision to automate a process or a complete operation has been taken, the costs to that organisation of not running this more e cient version of its production are crystal clear. Installation and commissioning then become a race against the clock.
But there are other reasons for wanting to accelerate these processes. When cooking oil company Brökelmann, based near Dortmund, Germany, wanted to modernise its endof-line operations, it built up enough stock to give KHS a three-week window in which to complete – among other tasks – the conversion of an existing
wraparound tray-packer into a palletiser. The current, ine cient, palletiser also needed to be dismantled.
In the end, the installation –which included the conversion
of KUKA robots to a palletising role – was complete and production could restart a er just over two weeks. Control units were also replaced and an Innopal RG grouping robot was installed at the infeed, while an Innopal RK carries out the actual palletising.
“With the optimised gripper head, the customer can now palletise and position packs with much greater precision,” says project supervisor for
KHS had only a three-week window
KHS Olaf Schütt. “Conversion has also optimised the dimensional stability of the pallets in general.” Since the installation, Brökelmann has made an additional investment in a new KHS InnoPET Blomax Series V stretch blowmoulder. Sometimes, time is lost not in installation but in waiting for the equipment to arrive. Talking about the XP15 autonomous mobile robot (AMR), director of automation at Big Box Jason Dyche says: “A trial and site survey can be set up in a matter of weeks, and installation from receipt of order can be in just four-to-six
Slim stackable design
Multiple i/o wiring options
Starter kit available
The XP15 AMR can be delivered in under six weeks
weeks.” The standard order leadtime for an automated guided vehicle (AGV) is over 12 months, Big Box claims.
According to Dyche, the AMR or Big Box Cobot can transport UK and Euro pallets or bins of up to 1.5 or even 2 tonnes. There is no need to set up a warehouse management system, he says, and navigation is via re ector stickers on the ceiling. “There is no programming, but a teach-in of the routes through an intuitive app,” he adds. “Manually drive the truck the desired route and save it.”
SIX-MONTH PAYBACK
Big Box says it o ers options for purchase or leasing, but that return on investment is less than six months. In the UK, the system has all necessary health and safety approvals, it adds, as well as a support team.
Operator training – or, potentially, recruitment – can create more delays in the race to have machinery up and running. As MVTec explains, the lack of quali ed personnel and of programming skills is o en cited as a reason for not installing machine vision.
The use of deep learning and AI means that outstanding results can be achieved in object and defect detection, says the company, using self-learning algorithms and so ware
such as MVTec’s MERLIC. Since no programming skills are required for this type of machine vision, industrial image processing can make
a valuable contribution to digitalisation for small and medium-sized businesses as well as larger ones, it points out. The German supplier
is represented in the UK by Multipix Imaging.
W www.big-box.uk/automation/
W www.khs.com
W www.multipix.com
Opening
Adapting to the opportunities and challenges driven by individualisation, labour shortages and disrupted supply chains; our autonomous mobile robots are emerging as key players in industry 4.0 transformation.
Find out how our range of AMRs can help transform your logistics and warehouse operations.
Visit: https://new.abb.com/products/
• Proven technology
• Sturdy robust design
• Quick and easy set up between size formats
• Supplied in either tape or hot melt application
• Various options available
• UK engineering support/install
Starting Smart Manufacturing
Rockwell Automation keeps a close eye on Smart Manufacturing, and told Automation UK about it
Among the rich array of live presentations at this year’s Automation UK and Machine Vision Conference (MVC) and exhibition, an exploration of Smart Manufacturing by Rockwell Automation’s Mike Loughran was one of the most enthusiastically received.
Loughran, who is director for intelligent devices, so ware and control for the EMEA North region, wasted little time in arriving at a de nition of his key concept. “Smart Manufacturing is a desired state a manufacturer is trying to achieve, where they can orchestrate and optimise assets and processes within factories and across the entire value chain,” he said, pointing out that Smart Devices, Smart Machines and Smart Systems are what allows that to happen.
He tackled another term which intersects with Smart Manufacturing, he said, and is o en used interchangeably
with it: Digital Transformation. He de ned this as the process to achieve Smart Manufacturing. “But it is not just about the technology alone,” he said. “It must include the people who are adopting the technology and the process they are a ecting.”
Digital Transformation is applicable across an entire organisation, he added, from sales and IT to production, and has di erent implications in every area where it is implemented.
“We should ask ourselves why we need Smart Manufacturing,” Loughran continued. “Is it just because of the technology and the buzzwords?” The answer to this question, he suggested, is ‘no’.
He listed common challenges across di erent industries, and came up with ve outcomes that Smart Manufacturing can help to deliver: optimising production; empowering the
Mike Loughran explained the importance of workforce empowerment in wider Smart Manufacture
case erector from Lantech
workforce; managing risk; driving sustainability; and accelerating transformation. This last point was about areas such as Industry 4.0 uptake, and capabilities such as digital twins and digital threads.
Robotics and analytics were just two of the routes to implementing Smart Manufacturing, he said, with others including Enterprise Resource Planning (ERP), Quality Management Systems and Distributed Control Systems.
Every year, Loughran pointed out, Rockwell commissions a manufacturer survey and report on the State of Smart Manufacturing (available on the company’s website). In this year’s report, 88% of companies surveyed said they have invested in, or planned to invest in, AI and machine learning. This is above the European average of 84%, and comparable to gures for the US.
Mike Loughran emphasised agility
He concluded: “Ultimately, Smart Manufacturing is about identifying what is important to your business, then applying a balanced approach to people, process and technology to achieve your immediate goals.”
But there was a postCovid caveat here. “These requirements and goals may and will change, sometimes rapidly, due to circumstances beyond your control,” he warned. “So, having the agility and exibility to adapt and thrive in a volatile environment is key to the
future of UK manufacturing.”
That was why he was passionate about making this a reality, he said, and hoped the audience was, too.
Meanwhile, outlining the scale on which Rockwell operates, Loughran highlighted sales of over $9 billion in 2023, its 29,000
ONE
employees and the fact that it is present in over 100 countries worldwide.
T 0870 242 5004
W rockwellautomation.com
OF THE MOST TRUSTED SYSTEMS
INTEGRATORS IN THE GLOBAL PACKAGING INDUSTRY
n Full system automation and integration
n Over 800 robot installations globally
n Compact, flexible footprints
n Speciality applications for bags, drums and bales
n Multi-line picking and palletising solutions from a single palletiser
n Sub 0°C freezer environment package options
Feature: Automation, robotics and vision
Collaboration is catalyst for R&D
Italy’s Cama hails a process of ‘co-creation’ as being the key to its new machinery innovation
Successful automation depends on many factors, but inevitably there are elements of co-operation and synergy in every project and – as Italian machine builder Cama discovered –these can play a central role in optimising a new integrated system.
When creating a single compact machine capable of taking product from three or more infeeds, each at a di erent rhythm, Cama worked with ABB business B&R. The result is a seamless t between its own Monoblock Top Loading (MTL) system and B&R’s ACOPOStrak magnetic track, which acts as an automatic bu er. And it is a result, according to Cama, which increases productivity while reducing machine footprint.
The system allows for decoupling of the process stations, optimising the ow of di erent products and cycle times. It also incorporates a simpli ed control panel.
predictive maintenance,” he says. “As a result, this solution requires less human intervention, thereby reducing the potential for human error. Remarkably, this solution also saves time, cutting changeover from 30 to 12 minutes!”
B&R global industry manager for packaging Wlady Martino explains the problem-solving process. “The challenge was the high throughput and the distance that the products have to travel: up to 14m,” he says. “In this sense, speed and dynamics become really important.”
The magnetic shuttle track has a top speed of 4m per second and acceleration of 50m/s².
Cama group sales director Alessandro Rocca calls the monoblock “interesting and complex”. “It makes use of augmented reality to access maintenance, changeover and spare parts, which can be ordered directly via a tablet, also enabling
WE’VE GOT AUTOMATED
ALL WRAPPED UP...
PACKAGING
Materials & machinery for the complete solution
Transit & display packaging
Fully-recyclable, recycled content, sustainable, anti-fog, barrier, MAP packaging and more...
High-speed equipment for demanding environments
Supported by expert engineers, across the UK & Ireland
‘Co-creation’ is a term that applies to more than the collaboration between Cama and B&R. As Martino explains, the fact that his company can accurately simulate the system as it is designed means that the customer, too, has a ‘co-creation’ role, allowing any changes to be made at an early stage.
Vice president of Cama Annalisa Bellante adds:
“We have always tried to stay one step ahead, with a large R&D team of young people.”
Cama held a large and successful press launch of the new MTL and ACOPOStrak combination in mid-May at its headquarters in northern Italy.
W www.br-automation.com
W www.camagroup.com
Cama and B&R worked closely in order to integrate the ACOPOStrak
Vacuum gets a grip on cost
Paulig, Belgium, is making savings with a centralised vacuum system
Integrating visibility and control across lines or even entire operations is one of the key objectives of automation – and not always straightforward to achieve. But for other key components in the manufacturing process, centralisation can be more manageable, as well as being healthily cost-e ective.
Paulig produces and packs tortillas at its facility in Roeselare, Belgium. It requires the constant availability of vacuum for, among other processes, modi ed atmosphere (MAP) thermoform- ll-seal and robotic pick-and-place of completed packs.
on a demand-driven basis.
“By centralising our vacuum supply with Busch, we signi cantly reduced the number of vacuum pumps required by our process, and vacuum is readily available,” says technical engineering manager Rick Vandenbroucke. “With a central vacuum system, we save €15,000 on annual energy costs.”
The company also makes an annual saving of €5,000 on maintenance for an operation which, it says, runs 24/7 with only two weeks closure every year.
“The Busch system not only ensures smooth day-to-day production, but also makes maintenance a breeze,” says Vandenbroucke.
Thermoforming of tortilla packs at Paulig, Belgium
If vacuum were provided on a machine-by-machine basis, each line would require three vacuum pumps. Instead, a er discussing its needs with Busch Vacuum Solutions, Paulig opted for a centralised vacuum supply. The number of pumps and, as a result, running costs, have been sharply reduced, with the central vacuum system running
“We don’t need to stop production in order to carry out maintenance on our vacuum pumps and, since they’re not installed inside the packaging machines, they’re much easier to reach and service.”
The current vacuum supply is designed for 10 packaging lines and consists of nine R5 rotary vane vacuum pumps, three PANDA vacuum boosters, three MINK dry claw vacuum pumps, and a vacuum vessel.
To further reduce energy costs, each pump is equipped with a variable speed drive.
T 01952 677432
W www.busch.co.uk
Feature: Automation, robotics and vision
ABB automates its in-house operation near Milan in Italy
There can be no better way of demonstrating belief in the automated systems you produce than by installing the very same systems in your own factories.
ABB has done exactly that in Italy.
The company’s instrumentation factory in Ossuccio, north of Milan, has seen its warehouse operation transformed by the introduction of a fully-automated storage and retrieval system. According to ABB, this has led to a 90 per cent improvement in overall logistics e ciency at the factory.
The transformation from a manual operation to full automation has come with the installation of two ABB OmniVance FlexBu er robot systems, which manage all loading and o oading activities.
TIME REQUIREMENTS CUT
As well as the improvement in overall logistics e ciency, the elimination of manual handling has reduced the time required for nal assembly of packages by 30 per cent. According to general manager of the ABB Measurement & Analytics factory Mariafrancesca Madrigrano, the improvement is of critical importance, since the process now handles one piece every three minutes.
“We wanted to improve logistics at the Ossuccio site, while also enhancing the entire manufacturing process,” she says. “We constantly strive for operational e ciency through innovation and are always looking
Storage makes efficiency gains
The Ossuccio site has OmniVance FlexBuffer robots operating storage and retrieval in its order handling
for ways to better address customer needs and ensure customer satisfaction.”
The two OmniVance FlexBu er systems are connected by a conveyor, with the ABB robots at each end managing order handling. According to the company, FlexBu er allows for easy transitions between bu ering, storing and sequencing tasks, and excels in e ciently combining temporary storage and sequencing functions, giving it a competitive edge over traditional systems.
For additional exibility, the mixed item variant of the FlexBu er allows the user to store a wide variety of box sizes, all handled by the same robot gripper. The dynamic racking positions mean that all boxes can be stored with minimal loss of space, says ABB.
Madrigrano emphasises that the system has improved working conditions for operators, alleviating the physical strain associated with the manual
handling of heavy loads. The workforce was reallocated to other manufacturing areas that required additional sta ng.
The Ossuccio factory is specialised in the production of pressure transmitters that enable industrial companies worldwide to measure, monitor and control applied force. These transmitters are essential to many safety functions, says ABB, as well as providing greater e ciency to multiple processes. Pressure measurement can also be fundamental to industrial digital transformation. The factory exports as much as 90 per cent of its production, the company adds. This operation is part of ABB’s Process Automation business, which works to automate, electrify and digitalise across all types of industrial sector, from energy, water and materials supply to consumer goods manufacture and transportation.
T 01908 350300
W www.abb.com
3D vision sensor for plug and play integration into gripper applications from Universal Robots
The perfect combination of powerful hardware and easy-to- use software makes it possible to easily implement vision sensors in gripper applications from Universal Robots. The core element of the ifm vision sensor is a 3D camera chip. It creates a 3D image using PMD technology and time of flight measurement. The UR+ plugin ensures smooth and quick integration of the sensor. It detects any object, even moving ones, and transmits its exact position and dimensions to the robot control. Never before was gripper navigation so easy! ifm – close to you!
Feature: Automation, robotics and vision
Production hinges on digital systems
From remote access to a more cognitive role in data management, digital structures
support automation
From the so ware that allows automation to happen at the shop oor level, and the systems to link data pick-up points and aggregate what is collected, all the way up to ‘top oor’ enterprise-wide infrastructure, essential production and management architecture is evolving all the time.
At Enterprise Resource Planning (ERP) systems specialist Epicor, product marketing manager Mark Feathers highlights the current proliferation of connected machines, robots and other assets. This means that tomorrow’s ERP systems will need to connect
seamlessly with Internet of Things (IoT) devices, allowing real-time data exchange to optimise labour, equipment and schedules.
“Sensors on machines and robots will feed information directly into the ERP,” he predicts. “With the continuing fall in the cost of a ermarket sensors, even older equipment can now be
seamlessly incorporated into manufacturers’ IoT strategies.”
He foresees ERP leveraging machine learning to predict maintenance needs, optimise production schedules and prevent downtime.
“This proactive approach enhances e ciency and further boosts the bene ts of continuing automation,” Feathers says.
“The increase in the number
ERP can support decision-making
has also led to a surge in the volume of quality-related data to drive continuous improvement,” he adds.
Epicor underlines how ERP systems are evolving as AI capabilities improve in parallel with the broadening out of automation and digitalisation. “They act as digital advisors, becoming more proactive and intelligent in assisting businesses,” Feathers explains.
“ERP is moving from a system of record to a system of insight that enables realtime decision-making and automation to optimise key business ows – both within an enterprise and across supply chains. Here at Epicor, we call this ‘cognitive ERP’.”
Beijer Electronics offers its WebIQ software, BoX2 base and Cloud VPN
Packline third
With more of a ‘bottom-up’ perspective, Beijer Electronics emphasises the role the company plays in managing complexity, while providing security and connectivity. Its latest systems, it says, enhance operational e ciency, enable data-driven insights and o er scalability, exibility, interoperability between di erent equipment and systems, and centralised management.
Beijer’s WebIQ so ware tool allows web-based visualisation and control applications for automation systems. It supports HTML5, CSS3 and JavaScript, says the company, o ering a range of widgets, charts, gauges, maps and other components for a manufacturer to combine into its own interface.
Sales director for the UK, Ireland and EMEA Nigel Dawbarn says businesses will o en ask what the bene t is for them of moving from a classic human machine interface (HMI) to this type of 100% web-based technology.
“The answer should depend on your system requirements and how you wish to design your visualisation,” he states. “Would you like to view your data on a phone, tablet or PC remotely from the system? Do you want or need the exibility to update your project in the future?”
Supporting the aggregation of data from di erent sources,
Beijer o ers the second version of its BoX2 base – a device which, it says, can be used as a web server, gateway, data collector and universal
protocol converter, allowing the connection of legacy PLCs and HMIs, for example. Also new from Beijer is its Cloud VPN which allows
BoX2 base to connect to cloud services such as those from Microso or Google.
W www.beijerelectronics.com
W www.epicor.com
Feature: Automation, robotics and vision
Food manufacture sees full range of automation
While robotics has a huge amount
to o er food and drink production,
wider automation is increasingly building
e ciency across many tasks
If one of the key objectives of automation in food and drink is improved e ciency, then the accurate and consistent collection of data has to be the starting point before any of those improvements can be implemented.
When Europe’s largest meat processing company Danish Crown wanted to improve e ciency, enhance sustainability and reduce costs, it turned to manufacturing intelligence provider Factbird to leverage advanced data analytics across its global operations.
The business faced signi cant challenges with unreliable data and a limited understanding of Overall Equipment E ectiveness (OEE), as senior plant optimisation manager Mikkel Simonsen explains. “Missing data, I would say, is the main problem,” he notes.
Of Danish Crown’s 80 sites, 50 are in scope to implement Factbird. By the beginning of June this year, 21 systems were already fully installed, says the supplier, with 13 more currently being worked on. In total, this means that 405 Danish Crown lines are
collecting and analysing production data using Factbird.
On some of the lines now monitored by Factbird technology, standardised data collection has led to a 15% increase in OEE. “We have improved very signi cantly on some lines,” says Christian Kessler, a site operator in Oldenburg, Germany.
According to the supplier, the transition to a data-driven culture has enhanced operational transparency, empowering both management and operators with real-time insights which facilitate a process of continuous improvement. In the case of Danish Crown, a ve-step strategy took the workforce through key stages such as training about the importance of data, validation of that data, improvements at the level of batch management and deeper analytics and insights into wider production e ciency. One of the key metrics for food and drink, notably for higher-value products and ingredients, has to be yield. In this context, data in the form of accurate measurement is essential, as is the
Mettler-Toledo (left) emphasises the role of combined inspection, and Factbird (right) highlights benefits of data acquisition and analysis at Danish Crown
Ishida’s system reconciles accuracy with speed
automated equipment capable of putting that data to good and e cient use.
When Malta-based Sunshine Snacks wanted to improve the speed and accuracy of its packing operation, it turned to Ishida Europe to recommend the most suitable system. Operations manager John Bartolo outlines the bene ts of the Inspira iTPS (Integrated Total Packaging Solution) that the company installed - a system which brings together Ishida’s RV series multihead weigher and an Inspira rotary bagmaker.
“Our old weighing system either gave away too much, a ecting pro ts, or too little, which meant that more time was lost to rework,” he recalls. “We’d o en have to slow down our previous solution to try and improve accuracy.”
This is no longer the case with the Ishida multihead. “The accuracy of the algorithm is astonishing,” he enthuses. “The machine calculated variables automatically and we’ve seen a signi cant improvement.”
Increased speeds bring with them additional, less predictable, bene ts. Accuracy is further improved because there is less chance of the snack avourings sticking to the weigher’s contact parts and skewing weight calculations.
With 23 SKUs in its range, Sunshine Snacks was eager to keep changeover times between products to a minimum. Fully automated changeover now takes ve minutes, rather than the 10 minutes it took with the previous system.
Systems which combine and integrate di erent types of equipment are characteristic of many automated processes, as in the case of the Ishida installation. One area where this phenomenon is most prevalent is in combined inspection systems.
Market manager for checkeighing and vision at Mettler-Toledo Garvens in Germany Frank Borrmann takes a further step back, over the gap between automated and manual inspection in food and drink. “By transitioning from manual spot checks to fully-automated inspection processes, manufacturers are slashing costs while enhancing accuracy and e ciency, plus compliance with product safety regulations,” he says.
Combination inspection systems –integrating checkweighing with metal detection, x-ray or vision inspection –are compact, streamlining operations and optimising e ciency, he explains. So, for example, the company has its CX35
system consolidating checkweighing and x-ray and the CV33 incorporating vision for label inspection.
Bene ts go beyond simpli ed access and operating procedures, says Mettler-Toledo, with its advanced data management so ware ProdX. “This automates data collection, recording inspection data in real-time and facilitating easy access,” says Borrmann.
There are other areas of automation in food and drink which are too easily taken for granted, such as clean-in-place (CIP) capabilities. Italian company Zilli & Bellini’s most recent plunger valve piston ller has improved lling accuracy thanks to the redesigned valve concept, says sales area manager Stefano Zilli.
“For some applications, the plunger piston ller is the ne plus ultra of food technology, in part because it is possible to have CIP completely controlled by the PLC, without needing to dismantle any part of the ller,” he says. “With this upgrade, it is possible to press the touchscreen and a mechanical device takes out the pistons from the cylinders. With this operation, you can run an extremely e cient washing cycle.”
Key bene ts, he adds, are consistent cleaning results, independent of the skill of individual operators, and a xed cleaning time for production planning.
The company’s equipment lls a range of food products into rigid packaging, including fruit pieces and pulp added into beverages, tomato paste and sauces with or without pieces. Speeds can be up to 1,200 containers per minute, and the company estimates it has around 2,000 machines operating worldwide.
W www.factbird.com
W www.ishidaeurope.com
W www.mt.com
W www.zilli-bellini.com
The Zilli & Bellini filler improves clean-in-place
Automation drives stronger efficiency
At Automation UK, a BARA panel tackled questions including customer involvement and detailed plans
The June Automation UK show in Coventry saw an experienced lineup of industry experts get their teeth into the question of how automation can help to drive out ine ciencies in manufacturing.
Chaired
by consultant
Philippa Glover, the seminar also included: Dr Martin Kidman, market product manager for safety solutions at Sick UK; Andrew Mason, sales manager for RARUK Automation; Oliver Selby, head of sales at Fanuc UK; and George Thompson, UK sales manager at Güdel
Lineartec UK, and also chair of BARA.
Thompson underlined the way in which a system integrator can “make or break” a project.
Fanuc’s Selby elaborated on this, and the way that a good integrator works with the customer.
Simulation reduces risk, says Fanuc
“They’ll do a line walk with you to identify which operations can be automated.
Shibaura Machine's SCARA and 6-Axis Industrial Robots. Offering control and precision for over 40 years.
actually create ine ciencies?”
Thompson gave the example of a glass manufacturer, where Güdel’s ‘lights-out’ proposals “scared the living daylights
out of them”, and they fell back on selective automation of processes.
Fanuc pointed out that the clear objectives should
piCOBOT®
include the long-term.
“Only 15-20% of the total cost of equipment goes in the initial capital expenditure,” Selby stated. n
They will be able to create a simulation, and by the time they build the line, it should be a risk-free build,” he said.
For RAR, the lack of an eye for detail can create risks in the automation process.
“Look carefully at what the operator is doing,” Mason cautioned. “Look at the whole task and make sure you include all of it!”
Sick UK’s Kidman summed up this point rather di erently.
“Don’t buy all your kit before you’ve properly analysed the task in hand,” he advised.
INVOLVING OPERATORS
Like RAR, Güdel emphasised the operator, but in a slightly di erent way.
“Be customer-centric,” Thompson recommended.
“Make sure people feel they’ve contributed to the installation.” That includes winning ‘buy-in’ from key operators. “For instance, if an operator can cut half a second o cycle time, that may not sound much, but it’s a lot over a day or a shi .”
Acknowledging this type of contribution is important.
Glover stressed the importance of clear goals, and asked: “Is there a risk that people can over-automate and
Breaking the barriers of cobot movement
Feature: Automation, robotics and vision
Compact machine design has created new opportunities
Space-e cient equipment design has always featured on the ‘shopping list’ of both machinery manufacturers and their customers, but advances in many di erent technologies – not least robotics – are allowing fullyautomated processes to occupy an ever-smaller footprint.
A ne example of this trend is Herma’s new labelling cell for pharmaceutical and healthcare products, the 211 HC RC.
“To bring together the necessary technology in the smallest possible space, we worked closely with specialists from Fanuc and Weiss Robotics,” says Gary Hopkins, robotics specialist at Herma.
“This has allowed us, for example, to utilise the world’s smallest fully-integrated servo gripper.”
The 211 HC RC is said to label and inspect up to 20 items per minute – specialising in those products which are unstable. It achieves this in an area less than three square metres. The operator’s only task, says Herma, is to remove batches of labelled product from the machine.
The CLG 30-006 gripper, which features in the system, and is here applied for the rst time to pharmaceutical labelling, was developed by Weiss. Up to now, typical uses of the gripper have been in the micro-assembly of electronics. All necessary settings can be controlled and operated via the Herma human-machine interface (HMI).
Innovation in limited space
The same full integration and centralised control applies to Fanuc’s SR-12iA SCARA robot. It has a maximum reach of 650mm, while speed-wise, it is able to maintain the necessary labelling and inspection pace.
“The epoxy coating, the foodsafe lubrication, and compliance with ISO class 5 make it the perfect choice for production environments with especially high cleanliness requirements,” says senior regional sales manager at Fanuc Thilo Schmelling. ISO class 5 corresponds to cleanliness class A as de ned by the EC-GMP guidelines.
The latest systems from Polishbased Tkmatik, with a track record in bottle and cap handling for cosmetics and toiletries, include the UNILINE 50 lling and capping monoblock. This again o ers all the bene ts of a compact design, with a four-head precision servo dispenser and two servo capping heads, each with a servo-driven li er, all within the same machine frame. Toolless changeover can be carried out by swapping one dosing system for another.
The company’s new UK
representative Acer Machinery Solutions explains that the monoblock uses a patented adjustable-format system of pucks, each with embedded RFID tags. It is able to accommodate a range of sizes and shapes of container, typically bottles or jars up to one litre in capacity, though adaptations can be made for larger volumes. Integrated scales provide feedback to the lling dispensers, says founder and managing director of Acer Machinery Emma Ridgway. The dispensing system is able to handle a wide range of product viscosities from free- owing liquids to pastes and scrubs, she says.
Supplementing the onboard Industry 4.0 technology, Acer points out, inbuilt cameras allow for the option of remote support and monitoring of events, should assistance be required. Reaching output speeds of 50 containers per minute, the machine’s full servo technology means product changeovers can be carried out in under 30 minutes. W acermachinerysolutions.co.uk W herma-labellingmachines.co.uk
The UNILINE 50 fills and caps in a small footprint using a system of special pucks
The Weiss gripper on Herma’s machine
Now robots move to meet any need
Experts
in more traditional
handling systems are seeking to combine established options with newer technologies
Tried-and-tested mechanical indexing and conveying systems are being brought together with the latest robotics to build in the necessary mobility within a production environment, in ways that optimise e ciency and cost.
Perhaps better known for its conveying systems, Interroll has an Autonomous Mobile Robot (AMR) which integrates with and complements those systems.
Like other AMRs, it uses a combination of sensors, vision, mapping and positioning technology to navigate safely around environments which are
vehicles or personnel.
The company’s AMR Top module integrates with its Light Conveyor Platform system, as area sales manager Roland Palm explains.
maximising productivity
“Our LCP platform is already well-known and used by manufacturers,” he says. “The AMR Top module o ers safe, fast and e cient integration to deliver a complete materialhandling process.”
module can dock very quickly and reliably with other parts of the conveyor system, and safe handling of items,” says Palm.
The AMR Top designed to handle items up
and LCP system in general is to 50kg in weight. The LCP can be mounted on to AMRs from
either Mobile Industrial Robots or Omron, using application. integration to deliver
The module uses infrared communication to dock with the LCP conveyors that it receives items from or delivers items on to.
“The solution we’ve
either a belt or rollers depending on the
The LCP system can be supplied with an in-built control system which allows four conveyors to be managed from a single control module, says Interroll. The company emphasises that while AMRs complement conveyors, they are no substitute for them, particularly in high-volume production settings where limited exibility is not a problem. AMRs work best with lower volumes, especially where there is considerable variety in possible product destinations or where these change over time.
Interroll with Omron technology
Robot Transfer
and newer technologies, specialist in linear motion systems Rollon might provide the example of its Steel Robot Transfer Unit (RTU), a rack-and-pinion track where a robot can be mounted to extend its operational reach and capabilities. According to the company, the robust design and use of steel pro les lend the construction an optimal sturdiness for moving large loads.
ease – and quietness – of movement. It is supplied with a standard cable carrier, gearbox and lubrication systems, and can be
integrated with any type of robot, says Rollon. This wide compatibility ensures that businesses can upgrade their automation
without the need for extensive modi cations to current setups, it adds.
W www.interroll.com
W www.rollon.com
In fact, the system’s combination of high speed and precise positioning favours a wide range of operations where repeat accuracy is important, from assembly and welding to materials handling, where even a minor divergence from preset parameters can impact product quality.
The company o ers two versions of the system. The rst of these uses a roller guide system, and is said to be a good t with all working environments, but especially those which are potentially contaminated, thanks to the lifetime-lubricated and tapered rollers.
A second version applies a recirculating guide system, which Rollon describes as being ideal for high precision and repeatability.
The rack-and-pinion mechanism features selfcentering inserts to facilitate
When automating coding and data quality control functions, individual vision systems are increasingly part of a unit performing multiple roles
The pharmaceutical industry has three key demands: precision, compliance and e ciency.
This is the belief of machine vision specialist Fisher Smith, and the reason why it has taken its most recent step into new equipment and enhanced capability.
Managing director of the company Iain Smith explains that it has helped to pioneer new options including the rst Cognex 7905V vision systems in the UK, helping to address challenges and streamline operations.
“In the pharmaceutical sector, accurate barcode reading and veri cation are critical,” he says. “Every product must be correctly labelled, and every barcode must be scannable and veri able to meet regulatory requirements and ensure traceability.” As he points out, traditional methods that are o en reliant on manual inspections are time-consuming and error-prone.
A key consideration in customer decisions to specify the 7905V was its dual application capability, says Fisher Smith. The unit handles both vision inspection and barcode veri cation simultaneously, saving time and reducing the need for multiple devices, and so minimising costs.
A second priority was the system’s ability to ensure compliance with all relevant pharmaceutical regulations, reassuring users that all legal obligations are being met
and that products comply with ISO 15426-1/2.
The third element in the company’s triad of needs was e ciency. “The 7905V reads and veri es barcodes at unparalleled high speeds without compromising on quality, ensuring that production lines operate at peak e ciency,” says Smith.
The company says that ‘e ciency’ could equally be applied to its “seamless” integration. “The system is easy to install and con gure, minimising disruption during the transition phase and allowing for quick implementation,” he explains.
Alongside the operational e ciency, product quality and regulatory compliance, the Cognex system has also given customers a valuable stream of data on which to base continuous improvement.
“As the pharmaceutical industry continues to evolve, so will the need for more sophisticated and integrated solutions,” Smith argues,
adding that the integration of this system marks a signi cant milestone in the sector’s journey towards greater e ciency, compliance and quality.
Regulatory compliance, this time in food and drink, was one of the drivers behind the introduction of a di erent type of data veri cation combination by Domino Printing Sciences.
“In January 2024 alone, the FDA [US Food and Drug Administration] issued 19 recalls for food products in the US, with 18 of them attributed to undeclared allergens due to labelling errors,” says the company’s director of automation, Adem Kulauzovic. “These gures highlight that printing and labelling ine ciencies are still very much present within a signi cant number of manufacturing facilities, despite recent advances in product coding automation.”
Domino has announced the launch of automated print and
Domino says that sourcing different functions, such as software and vision, from a single supplier can reduce complexity, costs and implementation times
The Cognex system in operation
label veri cation systems to help manufacturers reduce the risk of costly product labelling errors. What it calls its “end-to-end solutions” bring together two new products: Domino Automation and its R-Series i-Tech, part of its R-Series machine vision range for product veri cation.
Domino Automation is the company’s coding automation and printer management so ware, allowing for centralised creation and automated deployment of product labels, and so reducing the need for manual data entry. The i-Tech is said to be optimised for highspeed processing lines, with increased processing power. It is able to operate two cameras, if required, to suit wraparound applications.
The combination, allied with remote monitoring from Domino’s cloud-based services, is designed to work alongside the company’s full range of variable data printing systems. Components can be standalone or integrated as part of a full, closed-loop installation.
BREACHING BARRIERS
The supplier quotes the recent Industry Insights Survey for 2024 from the publisher of Machinery Update, Automate UK, which nds that over 80% of those surveyed identi ed automation as their primary challenge over the past year. Domino cites the report as saying that top barriers to the adoption of automation included cost, lack of internal knowledge and the inability to nd the right suppliers.
“When it comes to adopting automation, designing a solution that integrates various technologies while managing relationships with multiple suppliers can be costly and complex, posing a challenge for many businesses,” says Kulauzovic. “Our closed-loop solutions have been designed to o er all the bene ts of automated
product coding from a single trusted source, helping to reduce complexity and costs associated with lengthy product timelines.”
He adds: “In addition, our exible nance options – encompassing both subscription models and product leasing – mean
businesses can upgrade without signi cant capital investment.”
W www.domino-uk.com
W www. shersmith.co.uk
Ultra Premium Efficient Drive Systems
•Flexible, modular range of high e ciency, robust gearboxes with output torques up to 250kNm.
•Motors with e ciency levels up to IE5+.
•Intelligent frequency inverters with PLC onboard and parameter
Feature: Automation, robotics and vision
From inspection to sensing distances, laser has answers
If you wanted proof of the versatility of laser in a modern manufacturing setting, you could do worse than look at 3D inspection systems, where e ectiveness can be measured in the way applications have migrated from one original role to multiple end uses.
When scanware electronic rst introduced its SPECTRA 3D system, it was targeting quality control in multi-layer tablets, where inspection was so precise it was able to detect when just one layer on the tablet was missing. “But the application is versatile,” explains managing director of the German company Harald Mätzig, adding that the system has since been utilised for tasks from the detection of braille to the monitoring of aluminium blister formation.
The latest-generation inspection unit comes with a new graphical interface, described by scanware as being “sleeker” than its predecessor, and is driven by new so ware architecture.
The QI (Quality Inspection) so ware has an AI element to it, o ering system-based parameter suggestions and prelearned information to cut down on teach-in time, while also minimising human error.
New applications are being added all the time, says technical director Roland Burger.
“Our inspection systems for bulk and parenterals are already on-site with customers and improving productivity,” he reports.
PREVENTIVE MAINTENANCE
Since SPECTRA 3D operates in real-time, the error-recognition data in blister-formation can be carried over to the bene t of the forming tools. Any divergence from the correct shape can indicate excessive wear-and-tear in the tooling. Early evidence of consecutive errors or increasing error frequency allows early detection of a potential fault,
Laser-powered functionalities
The
which in turn facilitates preventive maintenance and, ultimately, reduction of line downtime.
At AP Technologies, director Martin Sharratt takes one or two steps further back, talking about photonics – the technology of light – in much broader terms.
“It is critical to the e ective operation of modern manufacturing operations,” he argues. “Opto-electronic time-of- ight (ToF) sensors are beginning to play a unique and critical role in robotic, surveillance and autonomous systems.”
In the case of ToF sensing, laser diodes provide real-time distance measurement by emitting a continuous modulated beam, where distance information is determined by phase shi .
“With compact, ruggedised, solid-state components, capable of accurate and consistent operation over long product lifetimes, it’s no wonder that this light-based distance sensing technology is increasingly deployed in applications from production line
control to autonomous vehicles,” says Sharratt.
He likens the technology to lidar, meaning that ToF can accurately measure distances from 1.5cm up to 100m, even in high ambient light conditions. These sensors provide higher accuracy, longer range and better immunity to interference than alternatives such as ultrasonic or infrared sensing, he says.
AP Technologies supplies ToF sensors from Broadcom. These modules pack a laser diode, driver electronics, reference detector, a custom ASIC with 32-pixel avalanche photodiode detector array, with control and readout, transmission and receiver optics with ambient light suppression, all inside a rugged housing measuring just 12 x 8 x 8mm. Six models are available for di erent application needs.
At the Automation UK show in June, Broadcom delivered a presentation on the role of ToF in manufacturing.
W www.aptechnologies.co.uk
W www.scanware.de/en
scanware system detects forming errors in aluminium blister packs
Ethernet module adds to efficiency
In a move that ifm electronic says will “revolutionise industrial automation”, the company has launched a new series of Ethernet modules for eld applications.
The AL 4XX series of decentralised digital input (DI) modules is said to act as a vital link between binary sensors and the eldbus. Their role is to enable smooth transmission of binary switching signals without the need for additional transmission systems. The company calls the series “The perfect addition to ifm’s IO-Link family”.
The company’s ecolink technology ensures that M12 connections on the cabling remain reliably ingressresistant, it adds.
In terms of durability and quality, the materials and production methods used are said to owe a great deal to ifm’s jumper cables in its EVC and EVF product series.
Instrument maker selects gearboxes
Measurement equipment specialist Rotary Precision Instruments (RPI) has chosen to use planetary gearboxes from Apex Dynamics, says the supplier, because of their fast delivery, low backlash, low noise and good value.
Key features and bene ts, says ifm, include the ability to transmit signals directly with eldbus topology for increased e ciency, as well as a robust design for reliable operation even in harsh environments.
Non-contact
AL 4XX includes a voltage supply system with an A-coded M12 connector and L-coded M12 connector with daisy-chain functionality.
T 020 8213 0000
W www.ifm.com
Like others, RPI had problems in the wake of the pandemic sourcing parts and keeping leadtimes down. As the world’s largest supplier of rotary devices, it was especially keen to source a gearbox that could t into the existing design for the rotary table of a co-ordinatemeasuring machine (CMM), used to measure components. CMMs cut down inspection times and costs for aerospace manufacturers, avoiding any accumulation of errors.
RPI’s QuadDualPurpose and LabStandard precision axes were developed to boost the e ciency of CMMs. Apex Dynamics’ AF Series
planetary gearbox – said by the company to be “highspeed” and “high-precision” –tted into the available space without modi cation.
“All the gearboxes we purchased are running smoothly and have met our calibration standards,” says RPI UK technical manager Adrian Blake. He adds that RPI is now using the gearbox in two products and looks forward to working with Apex on other designs in the future.
T 0121 227 5340
W www.apexdynauk.com
capacitive level detection sensor will remain reliable even when coping with residues over vessel walls
Baumer has developed a capacitive sensor suitable for non-contact level detection which, says the company, is able to overcome the challenges associated with micro lms or residues adhering to the inside wall of the tank or vessel.
The PL240 sensor can be attached to the outside of plastic or glass tanks with wall thicknesses up to 6mm, and will reliably detect point levels of water-based media such as cleaning uids,
milk or laboratory uids thanks to compensating adherence, says Baumer. The sensor measures 40mm x 40mm and can be attached to the external wall of containers, o ering high performance even with an air gap of up to 1mm. This means it can be used even where containers are swapped in and out of position, the company claims.
More conventional capacitive sensors can nd it
hard to di erentiate between the genuine level of a liquid and residues on the inside of the tank, leading to the risk of uids handling systems running dry. Alternatively, sensors may be adversely a ected by other external in uences, potentially resulting in switching errors. Increased automation has made industry more reliant on these types of non-contact sensor.
T 01793 783839
W www.baumer.com
The AF series planetary gearbox used by RPI
Pressure valve provides accurate control for pneumatic operations
Emerson is now supplying its AVENTICS series 625 Sentronic proportional pressure control valves, designed to deliver highly accurate electronic pressure control with the exibility to support sophisticated pneumatic applications.
Boasting a control deviation of less than 0.5%, the valves use data acquisition so ware making it possible to quickly start up, monitor and control them directly on a PC.
Pressure control is highly accurate
“Series 625 Sentronic valves are engineered to precisely control pressure, ow rate, power, speed, distance and angular positions,” says Nicolas Jacquet, director of product management for Emerson’s discrete automation business. He adds that the series joins an extensive portfolio of AVENTICS cylinders, valves, air preparation and pressure regulation systems.
Valves are available in sizes from 1mm up to 20mm and support a wide range of ow rates, from 55 litres per minute to 4,700 lpm, with pressure capabilities ranging from vacuum level to 50 bar. This range allows system designers to reduce the overall number of valves required for a single machine, says the company.
Housing material can be speci ed in di erent metals.
T 01695 713600
W www.emerson.com
Labelling, Coding & Marking Components
Servo motors add in functional safety for encoder mountings
Brusatori Electric Motors, part of the KEB Group, has introduced a new mechanical mounting system for encoders within its DL4 series of servo motors, meeting designated functional safety requirements in conjunction with the approved drive system.
KEB explains that legal specifications exist in the form of safety integrity levels (SILs), and compliance can minimise the damaging effects of system failure. SILs make it possible to quantify the degree of reliability achieved by each object that performs a safety-critical function.
Four encoders with safety functionality are planned, and a new resolver will be added. On the back of this design, the aim is to introduce new drives and brakes and integrate with automation PLCs.
T 01933 402220
W www.keb.co.uk
Cobot integrator turns to laser scanning for safety
Sick UK is providing a UK integrator of cobots for machine tending with safety laser scanners to monitor human proximity, either slowing the arm or shutting it down if anyone approaches too close.
ALM Engineering produces systems under its CoboTend brand which incorporate cobots from Universal Robots into a wheeled trolley, designed to be moved around from job to job in machine tending. Clearly, once the cobot is secured in place with no enclosure around it, safety is of paramount importance.
slows to a safe speed. If the second, inner perimeter is breached, the cobot arm stops altogether.
In ALM’s new design, two Sick nanoScan3 Pro safety laser scanners are positioned at opposite corners of the cabinet, providing 360-degree coverage. The scanners operate two perimeters.
If a person crosses the rst, outer perimeter, the robot
“With earlier versions of the CoboTend, we had to set up the safety systems using a laptop and more complex so ware,” says ALM commercial manager Matthew Thompson. “It took a lot longer, and the so ware was less easy to use than it is now.”
ALM believes the simplicity
and e ectiveness of the Sick safety system is part of the CoboTend’s overall appeal.
The laser scanners work in tandem with the sBot Speed –URCap safety system, which combines technology from Sick and Universal Robots. It is said to be easy to set up, with data fed back via graphics on Sick’s FlexiSo controller.
T 01727 831121
W www.sick.co.uk
Customisable load cell measurement chain gives wide choice of output options and broad range of configuration variants
Provider of test and measurement systems HBK has introduced a Load Cell Measurement Chain (LCMC), combining any one of 14 di erent HBK load cells and an ampli er unit.
HBK claims that what sets its LCMC apart is its potential for creating over 11,000 con gurations. Product manager for weighing technology Simon Kleefeldt explains to Machinery Update that these permutations are a function of the 14 di erent
load cells with di erent capacities, seven di erent options for measurement electronics, plus other more minor con guration choices.
“We are thrilled to o er our customers a wide choice of load cells combined with a wide choice of output options,” he says.
“This LCMC empowers our clients with an easy-to-set-up, tailored measurement chain
The LCMC is easy to integrate
Users can select the load cell and interface that best suits their machine or process requirements, allowing a precise match for speci c measurement needs, says
HBK, and one that can be seamlessly integrated into existing infrastructure on the ‘plug-and-play’ principle.
All 14 load cells are available with IO-Link technology, allowing smart functions such as preprocessing of data, selfmonitoring and warnings. Additional advantages include bi-directional sensor communication and ease of installation, says the company.
T 01223 389800
W www.hbm.com
The laser scanners use a safety system combining technologies from Sick and UR
Unit 4 Anglo Office Park, Lincoln Road, High Wycombe, Bucks, HP12 3RH Telephone: 01494 512228 Email: mail.uk@volkmann.info Website: https://uk.volkmann.info/
Unit 4 Anglo Office Park, Lincoln Road, High Wycombe, Bucks, HP12 3RH Telephone: 01494 512228 Email: mail.uk@volkmann.info Website: https://uk.volkmann.info/
Volkmann UK Ltd Unit 4 Anglo Office Park, Lincoln Road, High Wycombe, Bucks, HP12 3RH Telephone: 01494 512228 Email: mail.uk@volkmann.info Website: https://uk.volkmann.info/
VACUUM – TRANSFER SYSTEMS
CoperionK-TronGB
4 Acorn Business Park, Stockport,Cheshire,SK41AS T:01612094810
Volkmann UK Ltd Unit 4 Anglo Office Park, Lincoln Road, High Wycombe, Bucks, HP12 3RH Telephone: 01494 512228 Email: mail.uk@volkmann.info Website: https://uk.volkmann.info/
VERIFICATION
Weber Packaging Solutions
MacmerryIndustrialEstate, Tranent, East Lothian, EH331HD