Digital transformation is undoubtedly a key to efficient and competitive production. The example of the Leibinger Connect digital control centre shows how simple, yet precise and targeted steps can have a major impact.
Packaging machines are among the fastest systems in industrial production. Cycle times of just a few hundred milliseconds are hard to achieve. But no matter how powerful a machine is, it remains part of a finely tuned process chain: packaging, labelling, documenting, tracing. Only when all these processes interlock smoothly will the line achieve the productivity that is expected today.
The term „digital transformation“ therefore covers a wide range of possible projects, many of which cannot be implemented ad hoc as they tie up considerable human and capital resources. There is also the risk that an incorrect changeover could not only lead to delays in production, but also cause quality problems and rejects. Furthermore, inefficient utilisation of resources significantly increases operating costs. Circumstances that must be avoided at all costs in the high-speed production of packaging technology.
Labelling as part of the whole
Product labelling is a good example of the interplay of many factors. It usually takes place at the end of the line and at first glance appears to be a minor detail. In reality, it determines traceability, delivery and compliance with regulatory requirements. Here, too, the technology must be available at all times: reliably, without long start-up times, changeovers, malfunctions or maintenance ordeals. Robust mechanics and reliable, high-quality labelling performance ensure operation when every second counts.
Added to this is the shortage of skilled labour. Especially in maintenance or shift operation, it is a particular challenge to keep an eye on several packaging lines at the same time. This includes: Shuttling between halls, searching for causes of faults, checking consumables levels or coordinating maintenance. A central overview of labelling systems, ideally integrated into the ERP, saves time and reduces incorrect reactions. Leibinger Connect was developed for this purpose: The control centre offers networked monitoring of every connected printer unit at a glance, thus enabling maximum printer efficiency.
The system makes the difference
How does this work in practice? For example, a shift supervisor manages several lines with Leibinger labelling systems. Instead of working his way through individual messages or manual checks, he can see at a glance which printer is running, which is paused, where material is running low or maintenance is due. He also has an overview of all relevant production figures such as speed and quantities of the packaging lines. Am I on target for production today, or am I lagging behind? Individual analyses, whether monthly, weekly or daily, are also possible: everything is available directly in the dashboard and can be individually adapted to the company and to your own interests and needs.
Leibinger Connect enables predictive planning and rapid response before interruptions or delays occur. For the production manager, this means no unplanned downtime, clearer processes and better utilisation of resources, especially where staff are in short supply. The control centre provides these functions without the need for complex software projects. Leibinger Connect brings together what has long been available: data, machines and responsibilities.
ERP connection in demand
Especially in companies with SAP as the leading system, the integration of the machine world plays a central role. Leibinger has created a standardised interface for this purpose, with which labelling data can be used directly in the SAP shop floor. Status messages, consumption values or feedback from the line are immediately available. For IT, this is not a gimmick, but a further step towards greater data consistency. According to the Industry 4.0 Barometer 2024, this is precisely where many companies still have some catching up to do. Despite ambitious digitalisation goals, many systems remain isolated. An SAP connection like this can help close the gap between technical reality and strategic aspirations. In addition to SAP integration, a universal interface is available that can also be used to integrate Leibinger Connect into other systems such as ERP, BE, CRM, CMS or quality assurance.
„When it comes to line performance, attention is usually focussed on the big levers. Leibinger Connect shows that greater transparency in labelling can have a noticeable effect. And without any additional project outlay. For companies, this is often the first concrete step towards digitalisation with minimal risk.“
Michael Wöhrmann, Director Business Development at Leibinger
Current industry studies show: The need for action has been recognised, but implementation often remains hesitant. According to the Industry 4.0 Barometer, Europe lags behind the USA and China when it comes to the use of digital technologies. Cross-company data utilisation in particular is still seen as an obstacle. Yet it could make a significant contribution to efficiency along the supply chain. Leibinger Connect addresses precisely this gap with a solution that works immediately, can be flexibly integrated and quickly takes effect.
Digitalisation where it has an immediate impact
Many companies are open to digitalisation, but find it difficult to get started. According to an Allensbach study, over 80 per cent of packaging manufacturers are planning or implementing digitalisation measures, but only a fraction are making consistent use of these opportunities. Digital transformation does not have to encompass the entire plant. A targeted step with a direct effect is often enough. Leibinger Connect was developed with this in mind: centralised monitoring of all connected printers via a user-friendly dashboard for Leibinger customers, simply, quickly and without additional hurdles.
The cloud-based platform fulfils all current requirements for data security and interface capability. For companies that prefer an on-premises solution, the company offers the OPC UA-capable IQJet printer model as an option that can be integrated into particularly sensitive IT environments. The platform also fulfils the requirements of packaging companies in terms of data security, for example through encrypted communication and flexible access controls.
More than just a monitor
Leibinger Connect offers more than just monitoring. It provides the basis for strategic decisions: Which printers are in use and to what extent? In which lines are productivity and utilisation levels high, in which lines is maximum production output not being achieved or is the utilisation level too low? Where can we optimise and how? Individual evaluations make the system compatible with existing KPIs and optimisation processes. Maintenance information, real-time counter readings and flexible data sharing, for example with the responsible Leibinger partner on site, round off the picture. The insights gained can help to increase the overall equipment effectiveness (OEE) in a targeted manner.
packaging journal 3/2025
