More standardisation, less costs, more efficiency

Universal Pack adopts Siemens OPL guidelines to configure machine control and obtain modular, flexible sachet filling machines capable of providing real savings.

Internationally recognized manufacturer of vertical and horizontal sachet filling machines, Universal Pack has centred on innovation and technological improvement to offer their users the real benefits provided by leading-edge machines equipped with latest generation electronics, be these energy saving, greater flexibility or higher performance. In the case of the Gamma range of augur sachet filling machine range, Siemens technology has been seen to match the company's philosophy to the letter, providing the tools and support necessary to engender real innovation.
 
Following the Siemens OPL specifications
Universal Pack has therefore adopted the Siemens OPL guidelines to configure the machine control. These are directives, based on OMAC standards, which tend to establish open control architectures and a standardisation of electronic components so as to provide more flexible and effective modular solutions.
 
Latest generation hardware  
The Universal Series sachet filling machines use the Profinet fieldbus based on Ethernet technology, to manage the different types of communication of a production machine: from TCP/IP to Real-Time Ethernet communication between different automatic devices; the isochronous communication for synchronizing the typical communication of motion control applications up to incorporating Profisafe safety protocols and information related to energy savings with Profienergy.

Hence the Gamma series uses Profinet as a single communication bus for all features: from control to diagnostics, to commissioning and maintenance, ensuring end users ease of use, optimization and increased productivity.
In calculating the costs of running a manufacturing plant, the energy bill has long been under the magnifying glass for both the rising costs of energy production as well as the high potential for optimization. Universal Pack machines reach high standards of energy saving, using SINAMICS S120 drives with regenerative DC-Bus technology. Thanks to Siemens technology, for example, the Gamma sachet filling machine is capable of balancing the motor power internally and regenerate any surplus energy back to the mains. With the help of a Simotion FB the energy consumption of the machine can be analysed, displaying the value of the instantaneous power of the drives or other electrical quantities (the peak power absorbed or generated, the total energy consumed in Kwh...).

The end user only has to collect this data, accurately monitor the energy curve of the machine and use tools such as WinCC Powerrate to enable accurate reporting.
By adopting the concept of Siemens OPL on their machines, Universal Pack provides the end user a high degree of standardization in both hardware and software, and undoubted savings in the management of spare parts and routine machine maintenance.
Then, using the provided OMAC PackML data interface, even at the level of communication costs of integrating the sachet filling machine in a complete production line are minimized, among other things enabling the prompt performing of diagnostics for each component via the supervision system.
On top of that the machine is already set to supply the data needed enabling the end user to calculate and optimise OEE line productivity.                                  

Universal Pack and the Gamma series   
A leading supplier for the food, chemical, pharmaceutical and cosmetic industries, in 46 years of applied experience Universal Pack has sold more than 7000 machines and has developed methods for metering troublesome products, pouching them successfully, accurately and at high speed. Their sachet filling machines are highly efficient, requiring a minimum level of support and maintenance and are generally custom designed and built. Although the basic structure of the machines is standard, each and everyone of them is in some way unique, customized according to the product, sachet size, number of lanes, metering systems, etc ... In particular, the Gamma series automatic Universal Pack sachet filling machines are vertical continuous rotary motion machines, appropriate for forming and filling sachets sealed on 4 sides. They can be used with all types of volumetric dosing and for a wide range of sachet sizes and are appropriate for producing set width and adjustable length sachets (the sachet width format changes require the replacement of mechanical parts). Production speeds depend on the number of lanes and machine cycles. The number of lanes depends on the sachet widths while the cycle speed depends on the product, film, dosage, sachet size plus other factors.

Gamma series: technical specifications
Number of lanes: from 2 to 24
Type of pack: heat-sealed on 4 sides, round or shaped
Sealing method: through rollers and sealing grippers
Production speed: up to 5,000 sachets/min depending on the product and film characteristics, sachet format and number of lanes
Metering method: volumetric from 0.1 a 300 cm3