Advantages of an evolved digital twin

Universal Pack – which designs and constructs vertical packaging machines for single-dose packaging in the pharmaceutical and food sectors, both for powders and for liquids, - has developed a particularly innovative packaging line for the pharma context, accompanied by its digital twin, using Schneider Electric’s EcoStruxure Machine Expert Twin software: a complete 3D model enhanced by the developed solution, on which to operate and interact in real time in all the life-cycle phases, from design to after-sales, carrying out simulations of dynamics, logics, movements, imagining configurations and modifying parameters. This ultimately makes it possible to reduce time-to-market, facilitating also the training of technicians.

An innovative and sustainable line

The complete line for packaging pharmaceutical gel in stickpack sachets developed by Universal Pack is composed, besides of the bagger and sealer, of a station for stacking, counting and checking the weight of the single sachet, and of a forming machine that forms the boxes from flat die cuts and closes them after filling. There are two robotic elements, managing a total of 50 movement axes. The key automation components are supplied by Schneider Electric, starting from the control system with CPU LMX 802 Pro 2. The two series P4s robots, the Lexium 62 motion elements, the high efficiency SH3 brushless motors, the Altivar 320 speed variator and SLC safety system are also by Schneider.

The line guarantees the final customer further advantages in terms of sustainability both in the physical version and in its digital mode. We can mention the possibility of printing film in real time (starting from a neutral white base): without sacrificing on speed in terms of packets produced, it manages production lots and coil storage in a flexible way, with relative reduction in costs. It can also use recycled and recyclable laminate film, has solutions for real-time printing on reels of small batches, and adopts an innovative buffering system, which drastically reduces product waste. Thanks to the movement of Schneider Electric robotic element, in fact, it’s possible to eliminate individual off-weight product packets without having to throw away a whole row of packets on the trolley and reintroduce a packet with the correct weight, continuing the production cycle without interruptions. A further feature in the direction of sustainability derives from the adoption of energy and quality measurement systems, components such as the brushless motors, which can reduce energy consumption by up to 50%, and the use of components with the Green Premium™ label with which Schneider identifies its products with lower impact and greater efficiency, furnished with all necessary certifications and instructions for correct end-of-life management.