With the modular Styron packaging machine from Forpac, the stretch film for packaging the products is cold-stretched. This enables significant savings in energy and raw materials.
25 September 2020
The different versions of the packaging machine consist of individual modules that can be combined depending on the type of application and the speed of the production line. (Image: Forpac)
Whether round or square packaging - the Styron packaging machine from Italian company Forpac wraps a wide variety of products in cold stretch film to form compact packs. With this latest development, the company enables high energy and raw material savings. The Italian company relies on drive and automation technology from SEW-Eurodrive.
The coffee undergoes a long process before it reaches us in its fragrant form. From harvesting to roasting to bottling, there are many steps. At the end is the Packing the individual coffee packs into containers, suitable for the retail and catering sectors. To achieve savings in energy and raw materials, the developers at Forpac S.r.l. from Noceto, not far from Parma, were looking for innovative solutions. The experts in the field of packaging technology have studied the needs of the various sectors for a long time. And they have developed the corresponding expertise for their machines.
Cold stretch film: no need for an oven
With the development of the Styron packaging machine Forpac has launched an innovative and technologically sophisticated concept. The Stretch film for the packaging of cold-stretched products. This eliminates the need to heat the film. In addition to reducing the amount of raw materials used for the packaging, this energy saving has a positive effect. Another advantage is that the products are not heated due to the elimination of the oven. They are therefore Protected from thermal shocks and deformation.
The cold packaging technology for stretch film with the Styron system saves almost 90 per cent energy overall compared to conventional systems with thermal forming. (Image: Forpac)
Styron would therefore actually be the right answer to the requirements for Flexibility and versatility, which are becoming increasingly urgent on the market. However, as is so often the case with innovations, Forpac initially faced reservations from some of its business partners. In the end, it was forward-thinking companies such as Lavazza that were prepared to reconsider their views on product packaging and were persuaded by this solution.
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[infotext icon]Luigi Lavazza S.p.A. is an Italian coffee company based in Turin. It is now in its fourth generation of family ownership. It is primarily known for its espresso and exports worldwide. The Lavazza Group is currently present in more than 90 countries and has a network of over 4,000 partners. Net sales in 2019 totalled just under two billion euros[/infotext].
Strong partnership
SEW-Eurodrive Italy made a decisive contribution to the success of this project. The collaboration between the two partners resulted in the first prototype of a machine for packaging coffee cans. Here 62 per cent energy saved and the Film requirement reduced by 64 per cent be. The Styron packaging machine was equipped with drive and control technology from SEW-Eurodrive. Innovative technical solutions enabled a modular structure. Depending on the speed and product requirements, this can be configured in different versions from one to several modules.
Each individual machine module can contain between six and twelve axes. (Image: Forpac)
Each individual machine module can contain between six and twelve axes and fulfils a specific task (film feeding, packaging feed, wrapping). The individual machine modules are synchronised.
Sustainable drive solution
All feeding tasks are performed by the energy-optimised Movigear performance drive unit. It combines motor, gearbox and drive electronics in one system. It is designed in such a way that it can be used flexibly for different communication infrastructures. This makes Movigear performance suitable for all decentralised applications in the field, especially for general conveyor technology.
Movigear performance combines motor, gearbox and electronics in one housing and can be operated on all common Ethernet-based infrastructures. (Image: SEW-Eurodrive)
The drive unit has a high level of system efficiency, which means that it is regularly able to achieve a higher level of efficiency than conventional older drives. Energy savings of up to 50 per cent can be achieved. A decentralised inverter is mounted directly on the terminal box of the geared motor. This corresponds to energy efficiency class IE5 for motors.
The most extensive system configuration to date, with three modules for loose bottles and outer packaging, contains 46 drives. The highest control precision was achieved and a total energy consumption of 9 kWh was determined. This machine is equipped with a remote control. This allows it to be comprehensively controlled and continuously monitored.
Cold stretch film for za variety of packaging types
To date, the Styron packaging machine has been built with proven solutions for the food and beverage industry. It is protected by patents in over 150 countries.
(Image: SEW-Eurodrive)
„The customer was so satisfied with our solution that we have since received a follow-up order from Forpac. With an identical concept, these new machines will be fully equipped with MOVI-C.“ Bruno Docimo, application engineer and packaging industry specialist at SEW-Eurodrive in Bologna
Thanks to its modular design, it can be fulfil various production requirements. This includes numerous types of packaging for logistics and distribution, such as loose or primary-packed products, four or six-sided film wrapping and a wide variety of products, e.g. bottles, cans or packets. Styron takes into account all requirements for high-quality packaging. In addition to the general suitability of the packaging, its stability, the load on the pallets, the transparency of the film and savings on film and energy.
[infotext icon]SEW-Eurodrive Italy was founded in 1968 and is now based in Solaro near Milan. The Drive Centres in Turin, Bologna, Verona, Caserta and the sales office in Pescara ensure a nationwide presence. The Italian market organisation remains the Motto of the SEW Group Think global, act local loyal. It generates a turnover of almost 140 million euros per year. The food industry is also one of the main sectors[/infotext].
