From filling and labeling to bagging and palletizing, Mitsubishi’s automation products and solutions span the needs of the consumer packaging industry. With increased efficiency and decreased energy use, Mitsubishi Electric’s industry leading innovations ensure products are packaged with precision, speed and accuracy.
- Cost of Operation
- Machine Utilization
No matter the product’s shape or size, Mitsubishi equipment can make your packaging operation more efficient, precise and cost-effective.
- Bottle Filling
- Horizontal/Vertical Pillow
- Case Packing
Whether its filling cola or cough syrup, your machine’s applications must be synchronized perfectly just to get the bottle to the nozzle. With so many moving parts, keeping the high speed, continuous motion of conveyors and consistent flow rates of fillers failsafe requires sophisticated automation. To meet your needs, Mitsubishi designs cost-effective control systems that maximize performance and reduce errors.
ADVANCED CONTROLS WITH HIGH-SPEED NETWORKS
It is vital that liquids are fed accurately and nozzle heights are precise, so timing system components to coordinate at high speeds requires advanced, dependable controls. Mitsubishi’s motion controller CPU intelligently controls cam profiles with software systems. This advanced CPU – based on the iQ-R Series – can reduce errors and profile deviations. Mitsubishi’s software offers flexibility, adjusting to various bottle sizes without overhauling the entire system.
The motion controller on the iQ-R Series platform controls high-speed servo drives, ensuring accuracy in synchronizing rotational conveyors, nozzle controls and liquid pumps. Working with the open device-level network CC-Link IE, iQ-R Series controllers ensure bottle feed rates retain speed and accuracy. The iQ-R Series can also connect to upper-level systems through an Ethernet option module, which feeds real-time production data into ERP/MES systems. This provides continuous monitoring as well as insight into bottling performance, eliminating your need to rely on statistical data.
Whether it’s soda or cough syrup, if the labels aren’t affixed identically from bottle to bottle, the brand will lose value, no matter how high the quality of the product. During the labeling process, labels will stretch, warp or even tear if the bottles are not fed at a constant rate. In addition, labeling requirements can change, sometimes requiring cold glue, sometimes hot glue and sometimes shrinkwrap. Since application methods differ from vessel to vessel, your machine’s control architecture must be able to support variances while retaining productivity. To address labeling challenges, Mitsubishi Electric’s automation controls guarantee consistency.
HIGH-SPEED FUNCTIONS WITH ACCURATE RESULTS
Mitsubishi Electric’s iQ-R Series guarantees labels are affixed accurately. The iQ-R Series CPU logic controller controls rotary drums, feed roller brakes and bottle sensors with simple ladder logic programming, all while maintaining the high speeds you rely on to preserve productivity.
Through the high-speed iQ-R Series bus connection, the GOT2000 HMI provides a means of letting you interact with your machines. GOT2000’s high-res touch screen displays and controls monitoring, debugging and label parameter profile changes.
Less complex applications requiring interpolation and servo monitoring can depend on iQ-F products. The iQ-F family features easy system integration. With the FX5U controller, you gain synchronous control of four axes as well as hassle-free maintenance and reduced cost of ownership.
Horizontal / Vertical Pillow
From pastries to pharmaceuticals, pillow-type machines have to be flexible enough to accommodate the range of products they package. Given forming, sealing and cutting requirements, the various processes must be synchronized perfectly. Mitsubishi Elctric’s iQ-R Series is the ideal solution for pillow packaging applications.
FORM, SEAL AND CUT WITH FLEXIBILITY
Coupled with MR-J4 servo drives and SSCNET III/H network, iQ-R Series motion controllers meet the demands of pillow packaging machines. Programming is simple with the iQ-R Series CPU logic controller. iQ-R Series motion controllers easily integrate with user interfaces like the GOT2000, all while maintaining high accuracy. With the phase compensation algorithm incorporated into the motion controller, packaging cutters can be synchronized precisely with the conveyor, providing accurate cuts at high speeds.
The GOT2000 allows for flexible operation. A substantial amount of profiles can be stored in the HMI, so you can go from packing medium to large pastries with ease, as the packaging profile data specific to each product can be called up in the GOT2000. Such a feature allows your plant to improve productivity and reduce system downtime.
FAST YET GENTLE TO THE END
Packaging products is an awe-inspiring process, but if the product doesn’t make it to the end of the line unscathed, having synchronized many fast-moving parts was just wasted time. That’s why getting the final packaged product into a cardboard case requires the same sophisticated technology as all the processes that came before it. Case packers are built for speed, but they must also have a gentle rhythm so they do not damage the product being placed in the package.
MAINTAIN QUALITY AND PRODUCTIVITY
iQ-R Series controllers are designed not only to maximize productivity and minimize downtime, but it is also designed to be flexible enough to meet the range of demands of packing applications. The iQ-R Series Motion System is designed for complex systems with many moving parts. It provides a high degree of synchronization, preventing errors in processes such as box opening, taping and transfer conveyors. CC-Link IE serves as a cost-effective, highly responsive communication that keeps conveyor sensors, folding pneumatics and cutter sensors in sync. iQ-R Series controllers are a high-speed solution for packing systems, but it also prioritizes accuracy, which ensures products do not spoil while being boxed.
IT’S IN THE BAG
Bagging is a seemingly simple process: put the product in the machine and place it in a pouch. But in actuality it is a complex system with parts that must synchronize precisely and efficiently. To coordinate communication between the various devices that lead to successful bagging, Mitsubishi designed iQ-F Series controllers.
SMALL AND COMPACT
iQ-F Series PLCs offer a wide range of controllers with special function boards, adapters and serial communication boards to fit bagging applications. The FX5U PLC is a smaller solution with room for system expansion. It ensures communication among hardware for volume dosing, thermal heat sealing and axes for vertical intermittent motion.
Once bulk product has been accurately weighed, the RS485 serial communication sends a signal to the PLC by way of an embedded port. This opens flap doors at the appropriate time. With the SSCNET III/H servo system network and the simple motion controller, two independent axes can work together to start and stop simultaneously.
To account for vertical heat-sealing strips and cross sealing horizontal jaws, the FX5U PLC and FX3U-4LC temperature controllers are easily regulated to maintain a steady level of heat across the light metallic welding parts.
PALLETIZING MADE PALATABLE
At the plant’s start point and end point are pallets, and regardless of where the product might be, the application must ensure that the goods are stacked safely and ready for transport. These systems tend to have simple architectures without extensive servo controls, but that doesn’t dismiss the need for high-performance processes with low operating costs.
PALLETIZING GOODS EFFICIENTLY
As a flexible, total solution that emphasizes productivity, iQ-R Series controllers are ideal for palletizing applications. For applications that don’t require motion controllers, the simple modules provide up to four axes of accurate servo control. Suited for controlling directional axes, the simple motion modules use simple ladder logic programming and integrated utility software. Simple motion modules also feature easy setup and simple debugging.
The CC-Link IE open device-level network allows for simple connection to iQ-R Series controllers. It can also connect to other devices such as sensors. With reduced overall wiring, CC-Link IE has fast and deterministic communication of 1 Gbps.
Call us at 317-253-5900 to let us help with your packing application!