The merits and introduction process of designing Packaging Line and automating the system and actual case introduction

In the manufacturing industry, in order to improve their productivity, companies have implemented automation their production line by adopting robots and automatic transporting machines more than before. The labor shortage has been an issue in the manufacturing industry and there are companies solved the labor shortage by realizing the automation in the way of simplification of the job or reduction of the time. In the packaging line as well, the labor saving can be expected by introducing the system using parallel robots and articulated robots for the jobs with heavy burden in human power.

However, if the system designing is not suitable for the conditions of location and the products, bottleneck could be occurred in the process.

This article explains the importance of the system designing when the packaging line is automated, and the merits by automation. For reference to who is considering the packaging line, we introduce the process of automation and our actual case experience.

The importance of packaging line design

On considering the automation of your packaging line, it may not solve the actual problem the production site faces just by purchasing robots or automatic transport machines without deep consideration. And it may cost more than necessary, or cause another problem after installing the automation system.

To prevent those issues and make the most use of the system and human resources at the production site, the line designing should fit with the each production site. For example, the analysis of the problem occurring in the existing production line, the necessary space in the factory, or the facility layout should be examined. Another important point is whether you will get advantage more than the cost of the automation you pay for the packaging line.

The advantages of packaging line automation

The followings are the advantages of automatizing the packaging line:

• Solution to the labor shortage and reduction of labor cost
• Improvement of productivity
• Stability in quality
• Improvement in sanitation

Solution to the labor shortage and reduction of labor cost

The automation of the packaging line will lead to the solution of the labor shortage and the labor cost reduction. In automation line, robot or automated system operates the packaging job. As a result, the necessary number of workers in site can be reduced.

Improvement of productivity

The packing job by using robot has an advantage to handle the job in high-speed comparing to the human power. If the job is required to be done repeatedly or the process is based on certain rules, robot can handle those processes very well. Robot only needs a few minutes for the job that takes a few hours by human power. Another advantage of automation is reducing mistake in the packaging process. There would be more human resources free from the simple job who can be shifted to the high-value added job and the production site overall become productive.

Stability in quality

The mechanized wrapping work stabilizes the product quality. For example, in the human manual work, there would be variation of the packaging depending on the operator experiences and the condition of the day. But the robot, without relation to the experience of the operator, robot can achieve constant quality.

Improvement in sanitation

If the packaging line is automated, it is less frequent the product touched by human that make it easier to control the sanitation. In the production site where the food products are handled, the sanitation is highly important. Production by the factory where is sanitary managed leads to improved reliability with business partners.

The process of the packaging line automation

Tam designs, manufactures and sells our packaging line systems. The following are the steps of the introduction process.

1. Inquiry, meeting and understanding the specification
2. Internal test by packaging system
3. Offer the layout and estimated cost
4. Re-design and finalizing the cost
5. Order for the packaging line system, manufacturing and installation

1. Inquiry, meeting and understanding the specification

When we receive an inquiry from the customer who desires laborsaving system or improvement of quality or sanitation, we meet the customer and check the required specification. In the meeting, we learn and examine the product character, installation space, the supply of packaging material to the system, working area, the problem the customer has and conditions. The meeting memo is submitted to the customer in order to sharing the mutual recognition.

2. Internal test by packaging system

Along with the meeting, we test internally the packaging line system whether it meets the customer’s requirement. The test result will be submitted to the customer and share the bottleneck. The test run is repeated several times and the issue found in the process will be solved.

3. Offer the layout and estimated cost

Based on the test results, the layout and rough pricing is confirmed with the customer.

4. Re-design and finalizing the cost

If the rough pricing does not match to the budget, we redesign the layout of the packaging line to make it closer to the budget. Once the layout is determined, the final cost is estimated.

5. Order for the packaging line system, manufacturing and installation

Once the final price is determined and the formal purchase order is received, we start the manufacturing the line system. On the installation of the packaging line, we support the installation work and the service after installation.

Packaging line introduction case example

The following case is the packaging line introduction we have been asked for by the soft cookie manufacturing company.

The trigger and the purpose of the system introduction

Before introducing the packaging line system, their products are packed in flat plastic bag by hand. The main purposes of this case are the labor shortage of the packing job and improvement of the sanitation. As they desire to mechanize the packing processes, Tam offered packaging line system.

The technical bottleneck and the point for solution

1. The line system has to be installed within the requested space.
2. To supply the cookies in fixed pitch those were used to be supplied randomly.
3. To prevent damage on the cookies when opening the bag and taking it out

To solve the above issues, we proposed to change the system from the method of filling the product as it is in flat bag, to the tray that the cookie can be placed in set position. By using tray, even the soft cookie can be taken out without damage. We thought it should be advantage not only the solution for labor shortage but it reads the improvement of the product value.

After deciding using tray, the system was designed as the combination of waterfall method + dropping shutter for placing the product into a tray in order. The scheme of this system is to array the cookies in order by using several conveyors, and then drop the each cookie into a tray by dropping unit. The cleaning of the system is easy, and the sanitation issue is cleared.

For the completion of the packaging line system, the product character has been checked and the several meetings with careful examination have been held. In the result, we received high evaluation from the customer on the system from the beginning of inquiry to the completion of the installation.

Tam has more experiences of the packaging line other than the introduction case of above mentioned waterfall method. The system integration combined with the industrial robots such as parallel robot and multi articulated robot are also available.

• - Pillow bag product casing system by top-loading accumulated caser
• - Cup product casing system consists of the print detection, liquid leaking detection by camera and top-loading accumulated caser
• - Powder filling system consists of the degassing device, conveyor transfer, sealer and metal detection device.
• - Powder filling system consists of pre-made bag filling machine, casing by using parallel robot (or multi articulate robot), printing device and Weigher.
• - Bottle filling system consists of bottle feeding device, air cleaner, rotary filling machine and capper.

See the details of the Line system here

System design and automation is the crucial point for the improvement of productivity.

Automation of the packaging line would lead to the merits of labor cost, improvement of the productivity, stability of the quality and improvement of sanitation. However, the system introduction should need the well-examined design for obtain these merits.

Tam offers our service of design including the integrating the reasonable peripheral devices, manufacturing and after service. We have years of experiences of the systems such as the parallel robot casing for HFFS pillow bag including printing device and weight checker, the top-loading casing system for VFFS pillow bag, and etc. Please feel free to contact us when you consider automation of your packaging line.

Tam Contact to: tam-overseas@tam-tokyo.co.jp