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For the production of small batch sizes in conjunction with a broad product portfolio, manufacturers of consumer goods require systems that offer optimum agility and flexibility. For bundling products in film packaging, a new stretch bundler from Pester Pac Automation sets standards in terms of automated processes and sustainable packaging materials.
„Our new stretch-bundler is intended to be a milestone for sustainable and economical packaging processes in the consumer segment that meets the latest trends and the current requirements of our customers,“ emphasises Frank Resch, Technical Director Business Unit Consumer at the Pester Pac Automation GmbH. The development team's objectives encompassed a large number of parameters: The system should open up new ways for safe packaging, handling, transport and shelf-ready packaging and thus operate more efficiently, sustainably and intelligently than existing solutions on the market. In addition, maximum machine efficiency and fast format changes with short changeover times for the production of small batches were a must.
Automation with innovative robot technology
The result is impressive: safe and stable stretch film packs are produced without the use of a shrink tunnel. The flexible PEWO-pack 600 high-speed system achieves a performance of up to 60 packs per minute. This is around 80 per cent faster than conventional stretching processes. It can almost all products from the cosmetics, health care or personal care sectors such as moulded bottles, aerosol cans, jars or folding cartons are processed and shelf-ready packaging is also an option. The new stretch bundler can also be quickly and easily integrated into upstream production.
„The new system also offers a number of advantages in terms of automation,“ explains Resch. Thanks to the use of modern robot technology, the PEWO-pack 600 demonstrates sensitive handling even for high-speed applications. The Fully automatic and tool-free format changes allows a quick and easy changeover for new tasks.
The agile Delta pick & place robot offers flexibility for a variety of different applications. It groups and configures the incoming products in the specified formation. The Pester Specially developed gripper technology enables quick and easy product changes in less than three minutes. Depending on the product and configuration, the high-speed stretch-bundler can process 360 products per minute in a single lane with its two robot units.
In order to guarantee optimum control for all components, Frank Resch and his team decided in favour of Rockwell Automation technologies. The Centralised control for the robot enables extremely simple operation and maintenance. The company had already had excellent experiences with the products and solutions in previous projects and had also learnt to appreciate their interoperability.
„Rockwell Automation provided essential support for our new development. With this technology, we were able to achieve the ideal level of automation for our customers“ requirements."
Frank Resch
Intelligent operation - digital and simple
One of Pester's most important strategic business areas is digitalisation. The company aims to set new standards once again with new digital solutions. For example, communication between the machine and operating personnel is intuitive and simple.
„All of our machines are equipped with a new generation of HMIs with interactive 3D visualisation for intelligent machine operation and predictive maintenance. We also offer support for process improvement in real time with our remote service and OEE monitoring.“
Frank Resch
Use of alternative films
The implementation of sustainable production processes is a high priority at Pester. The innovative stretching system combines numerous advantages for this. One Energy-saving packaging process for stable, resource-saving film packaging with maximum transport protection for the packaged goods sets trendsetting impulses for end-of-line packaging. The stability and safety of the packaging units required for transport has been confirmed by a certified transport test carried out by an independent testing institute.
Compared to a conventional shrink-wrapping application, the new machine concept allows up to 75 per cent of electrical energy and around 30 per cent of production space saved thanks to the compact machine design can be realised. A reduction in packaging material requirements of between 30 and 50 per cent can be achieved, depending on the application. The system can be used to process fully recyclable plastic monomaterials as well as packaging materials with a high recycled content without compromising machine performance.
A holistic life cycle analysis by the renowned ifeu Institute shows the ecological benefits of using stretching technology: on average 50 per cent material savings with the alternative packaging system compared to a shrink application with „virgin“ PE films (30 µm). Eight relevant impact categories and all known disposal scenarios for the packaging material were analysed and compared. Emissions can also be reduced by half.
Flexible all-rounder in product handling
The system has been impressing top players in the consumer industry since its market launch at the end of 2021 and is used by well-known companies worldwide. The incoming products are fed to the film curtain via a slide-in unit. Controlled film transport units are responsible for the stretching process in conjunction with the sealing system. The film curtains with Tightly wrapped in stretch film, the containers are stable and sturdy. Various multipacks can be produced, which are transferred to the downstream packaging process in the required configurations.
„We have incorporated the latest trends and requirements of our customers into this new development. The system offers maximum flexibility for small batch sizes and is ideal for use in 24/7 operation with reliable machine performance. We have invested a great deal of commitment and dedication to detail in this system and integrated state-of-the-art components at the highest level of automation. The further development of sustainable production processes for our customers is a matter close to our hearts. We are thus opening up new dimensions for the modern consumer packaging of tomorrow.“
Frank Resch
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