{"id":70978,"date":"2022-11-10T14:40:02","date_gmt":"2022-11-10T13:40:02","guid":{"rendered":"https:\/\/packaging-journal.de\/?p=70978"},"modified":"2022-10-26T14:44:12","modified_gmt":"2022-10-26T12:44:12","slug":"cardboard-instead-of-plastic","status":"publish","type":"post","link":"https:\/\/packaging-journal.de\/en\/pappe-statt-plastik\/","title":{"rendered":"Cardboard instead of plastic"},"content":{"rendered":"
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Because it no longer wanted to sell its dessert cups in shrink-wrapped plastic trays, the British company Premier Foods invested in a combined packing and palletising centre. The cups are now packed in cardboard boxes using tray erectors and palletisers and then palletised fully automatically. At the same time, the palletising centre disposes of two other packaging lines. The entire system was successfully accepted in February 2022.<\/strong><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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As one of the UK's largest food companies, Premier Foods employs over 4,000 people at 15 production sites and branches across the UK. The brand portfolio ranges from flavourings and seasonings, sauces and accompaniments, convenience foods, snacks and soups to aseptically packaged desserts. The Group also manufactures products such as cakes and desserts on behalf of many food retailers in the UK.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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At the Ambrosia Creamery, Premier Foods produces the UK's favourite rice pudding and custard products as well as numerous other desserts.<\/p>

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The aim was to create a modern multipack format<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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The first packaging system from A+F went into operation at the Lifton site back in 2012. \u201eThe most recent collaboration was about creating a to develop a modern multipack format for our popular dessert cups<\/strong>. At the same time, we wanted to switch to a more sustainable carton solution,\u201c summarises Graeme Strike, the project manager at Ambrosia. At that time, the filled cups were placed in an open plastic tray, which was additionally sealed with a shrink film before palletising. \u201eNow we pack our cups in solid cardboard sleeves and corrugated cardboard boxes<\/strong>.\"<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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The MultiFormer tray erector forms the desired packs from the sleeve and wraparound tray fully automatically.\n(Image: A+F)<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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In addition, a to find a suitable system layout in order to realise the planned palletising centre with integrated packaging unit in the planned hall.<\/strong> to be able to. In addition, all existing options, from the cup filler to product routing, were to be retained. \u201eThe flexibility of the design of the packaging unit consisting of tray erector and labeller was extremely important here. This ensured that the cups could continue to leave the filling machine in the established format and still be processed seamlessly by the new packaging and palletising line,\u201c explains Strike.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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The existing systems could be easily adapted to the new conditions. The order included the layout, two new palletisers, the conversion of an existing palletiser, a MultiFormer tray erector and a SetLine type palletiser, all the necessary conveyors<\/strong> as well as the mechanical and control-side connection to the specified interfaces. Two spiral conveyors were purchased and integrated as a general contractor. External units such as X-ray\/checkweighers, inkjet printers, pallet wrappers and pallet and carton labellers were also taken over.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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When planning the system, special attention was attention to the most energy-efficient operation possible<\/strong> - One of the aims here is to minimise the use of costly pneumatics. Consequently, the latest servo and three-phase drives are used and vacuum pumps replace conventional venturi vacuum generators.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Investment review with \u201edigital twin\u201c<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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The pallet type is changed on the palletisers used via stored product preselections. The same applies to the layer pattern.\n(Image: A+F)\n<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
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Assembly in Lifton began at the end of 2021, after which the new packing and palletising centre reached its specified output in a short space of time. Successful acceptance followed just a few weeks after commissioning in February 2022. The \u201edigital twin\u201c tool was also helpful. With this clarified via a computer simulation in the run-up to an investment how the task set by the customer can be realised in a technically and economically sensible way.<\/strong> can be realised. In the Premier Foods project, this related to the design of pallet transport. However, the \u201edigital twin\u201c goes far beyond pure computer simulation. The tool precisely controls the PLC that will be used by the customer, which in turn controls the simulation. The results of these tests, which were carried out almost under operating conditions The knowledge gained helps to optimise machine design and subsequent commissioning at the customer's premises<\/strong>.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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The packing and palletising solution is currently used in two-shift operation. The palletiser forms the packaging variants: 2 cups x 1 layer = 2 cups, 2 cups x 2 layers = 4 cups and 3 cups x 2 layers = 6 cups. Its nominal output is 304 cups per minute. The tray erector subsequently forms the required Container consisting of sleeve and wraparound tray<\/strong>. Its rated output is 19.0 packs per minute for the 2-cup sleeves and 12.7 packs per minute for the 3-cup sleeves. The palletiser for the new carton packaging also has a rated output of 19.0 packs per minute. The other two palletisers simultaneously dispose of two other packaging lines. Their rated output is 13.9 packs per minute each.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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\u201eWe knew the capabilities of the company and its components,\u201c summarises Strike. The framework conditions were more challenging, as the project was carried out against the difficult backdrop of the UK's exit from the EU and the COVID pandemic. \u201eDespite these completely new challenges, the A+F team always worked closely and cooperatively with us. This was certainly one of the key factors in ensuring that this project was realised on budget and on time. We can all be proud of that.\u201c<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Author: Michael Hafer, A+F Automation und F\u00f6rdertechnik GmbH<\/a><\/em><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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More news from the magazine <\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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\n\t\t\t\n\t\t\t\tIntelligent weighing technology saves resources\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t
\n\t\t\tGreenyard is equipping its high-speed lines with intelligent weighing technology from Mettler-Toledo, thereby significantly reducing the safety margin during product filling.\t\t<\/div>\n\t\t\n\t\t\n\t\t\tRead more \"\t\t<\/a>\n\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t
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\n\t\t\t\n\t\t\t\tFaster to sustainable packaging with AI\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t
\n\t\t\tThe Hamburg-based start-up One.Five uses artificial intelligence to find the optimum packaging faster from the wide range of paper types and coating options.\t\t<\/div>\n\t\t\n\t\t\n\t\t\tRead more \"\t\t<\/a>\n\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t
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\n\t\t\t\n\t\t\t\tPaper packaging for special requirements\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t
\n\t\t\tThe sister companies Kapag (Switzerland) and Oppboga (Sweden) support customers in switching from plastic to renewable raw materials with the renewable Changemaker paper and cardboard grades.\t\t<\/div>\n\t\t\n\t\t\n\t\t\tRead more \"\t\t<\/a>\n\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t
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\n\t\t\t\n\t\t\t\tFibre-based packaging: The path to industrial scaling\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t
\n\t\t\tFibre-based packaging is at a technological turning point. How is series production possible?\t\t<\/div>\n\t\t\n\t\t\n\t\t\tRead more \"\t\t<\/a>\n\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t
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\n\t\t\t\n\t\t\t\tPackaging users | Irony in the luxury segment\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t
\n\t\t\tIn his new column, Harald Braun, our packaging user, shows why luxury products sometimes deliberately forgo glamorous packaging. The deliberate break in image - from grey cardboard to sober typography - can even be a sign of strength in the premium segment.\t\t<\/div>\n\t\t\n\t\t\n\t\t\tRead more \"\t\t<\/a>\n\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t
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\n\t\t\t\n\t\t\t\tMore than a prompt\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t
\n\t\t\tThe start-up Pyx is managed by the founding team Stavros Kyriakidis and Otto Hefner.\t\t<\/div>\n\t\t\n\t\t\n\t\t\tRead more \"\t\t<\/a>\n\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t<\/div>\n\t\t\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>","protected":false},"excerpt":{"rendered":"Premier Foods has invested in a combined packing and palletising centre so that dessert cups are not distributed in shrink-wrapped plastic trays.","protected":false},"author":1,"featured_media":70988,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"__cvm_playback_settings":[],"__cvm_video_id":"","rank_math_description":"Damit Dessertbecher nicht in geshrinkten Kunststoff-Trays vertrieben werden, investierte Premier Foods in ein kombiniertes Pack- und Palettierzentrum.","rank_math_focus_keyword":"pappe,plastik","rank_math_title":"","csco_display_header_overlay":false,"csco_singular_sidebar":"","csco_page_header_type":"","csco_page_load_nextpost":"","csco_post_video_location":[],"csco_post_video_location_hash":"","csco_post_video_url":"","csco_post_video_bg_start_time":0,"csco_post_video_bg_end_time":0,"footnotes":"","_links_to":"","_links_to_target":""},"categories":[28],"tags":[59909,38,59908,70,39],"class_list":{"0":"post-70978","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-aus-dem-magazin","8":"tag-af-automation","9":"tag-lebensmittel","10":"tag-magazin-08-2022","11":"tag-verpackungsmaschinen","12":"tag-verpackungstechnik","13":"cs-entry","14":"cs-video-wrap"},"acf":[],"vimeo_video":null,"_links":{"self":[{"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/posts\/70978","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/comments?post=70978"}],"version-history":[{"count":0,"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/posts\/70978\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/media\/70988"}],"wp:attachment":[{"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/media?parent=70978"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/categories?post=70978"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/packaging-journal.de\/en\/wp-json\/wp\/v2\/tags?post=70978"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}