Single controller for a HFFS system

Implemented by Martini on its  MLV130 flowpack, the new single NJ501-1400 Sysmac Machine Controller helps to increase performances and reliability.

Film changes without stoppages, 30% less energy consumption, highest quality sealing (even for eco films), major maintenance cost savings: based on proven VFFS single controller, Martini’s new HFFS (Horizontal Form Fill and Seal) system is 10% faster in production partly thanks to Omron’s new single NJ501-1400 Sysmac Machine Controller.

Film changes without stoppages
Not only is Martini’s new HFFS system 10% faster in production, it also enables automatic changing of packaging films without machine stoppages, saving time and eliminating waste. It’s thanks, in part, to Omron’s new single NJ501-1400 Sysmac Machine Controller, which recently replaced two separate controllers to provide unified control of Martini’s highly popular MLV130 system. A system that now has a double-sealing head and Long-Dwell profile, as well as a volumetric dosing unit for fast, precise weighing.

Highest quality seals
Also, a new Omron temperature controller in the system helps to reduce the time needed to reach the right sealing temperature and to maintain the right temperature during machine transitions, such as machine start/stop or production speed changes. High quality sealing is becoming increasingly challenging as the industry moves to more sustainable packaging solutions, which range from thinner plastic films to multilayer packaging and recyclable films for eco-packaging. Now these challenges are being fully met with the new Omron temperature controller, which reduces the time needed to reach and maintain the correct sealing temperature during machine transitions such as machine start/stop or production speed changes.
«The quality of the packaging seals is a key benefit of our solution» said Francesco Gusson, Chief Engineer of Electronic Dept. «The dedicated packaging algorithms of Omron’s NX-TC temperature controller allow us to provide our customers a machine that can deliver the highest quality seals for a very large range of hot sealable packaging films».
The Sysmac NJ501-1400 machine controller by Omron allows more flexible production.

Extreme small-lot flexibility
Changing consumer demands mean that producers must deliver a wider variety of products and smaller size lots. And that means that new packaging machines need to be able to switch production quickly, with minimal changeover time between runs. With its unified control system, the new Martini system can make changes to the motion profiles on the fly, adapting itself quickly to changes in production. It allows bags length and production speeds to be changed without wasting material or stopping the machine. For example, machine homing only needs to be performed when the machine is first powered up, to set up the initial position. Afterwards, by using absolute encoders and software programming, the machine can return automatically to the right axis position in case of any problem or format changes, and can immediately restart production without wasting time to perform homing.

How it’s all achieved
By replacing the Omron CJ Controller and Motion controller MCH72 used in the previous solution with a single NJ501-1400 Sysmac Machine controller, the new system supports more flexible production. The controller manages both the packaging and dosing nodes over an EtherCAT network. The packaging node includes NX I/O for digital and motion inputs such as the encoder and high-speed inputs and all the temperature adjustment functions. The dosing node includes NX digital and analog inputs and a communication module to interface with Martini’s customized hardware for high speed and high accuracy weighing and dosing. Through this node the full-motorized movements of the doser are controlled, thus substituting the pneumatic devices and obtaining a relevant reduction of energy consumption.
While reducing change-over time between runs helps boost Overall Equipment Efficiency (OEE), a high throughput during production runs is still key. With its single controller and user-interface, the MLV130 delivers a 10% increase in production speed, processing up to 130 packages/minute with a package length of 340 mm.
With the availability of all the machine data and configuration parameters, downtime and maintenance costs are also reduced. Having digital access to all the configuration parameters for the machine enables remote assistance, which reduces the cost of maintenance support. Martini engineers can simply connect to the machine remotely to access all the devices and quickly resolve issues even when a skilled engineer is not present at the customer location. And a digital troubleshooter helps users to easily resolve specific machine conditions or change settings. Finally, by collecting and processing data in the cloud, Martini can even identify potential issues and perform preventive maintenance in order to further increase machine efficiency and program the necessary assistance service efficiently.

From VFFS to HFFS, with modular SW blocks
Omron supported machine analysis and configuration drawing on the two companies’ previous collaboration in designing the vertical flowpack machines. This allowed Martini to develop a modular software structure, which has increased machine design flexibility, based on proven software libraries and software modules. The modular software blocks allow Martini to quickly adapt machines to meet new trends in technology and to address also changes in product demand. They also help to reduce development and engineering time, allowing the company to tailor the machines to specific customer requirements in very short time frames.

Better sealing with AI             
To handle all these different types of film, while still delivering the highest packaging quality and cutting precision, Omron developed a new approach for the sealing system. They developed a new bendable thermocouple sensor, which allows the temperature to be measured very close to the seal-jaw surface. Moreover, the machine uses Omron’s new NX-TC temperature controllers, which integrate dedicated algorithms to deliver highly stable surface temperature measurements, thanks to Artificial Intelligence capability. This innovative solution means that the MLV130 can measure and control the sealing temperature very precisely. Temperature control is significantly less affected by the machine status (e.g. ambient temperature, sealing speed, film specifications, etc.) and the typical temperature drop when changing operating condition has been reduced by up to 20%.