When the scrap rate on the chocolate ice cream packaging line began to climb, the company needed an engineering solution for this problem. The company's final solution uses Emerson CT's drive, cutting the scrap rate by 90%, and quickly recovering the return on investment in just a few months!
The accuracy of the synchronization between the transmission speeds is gradually reduced, and the deviation is gradually increased. Together with the internal activities of the packaging, the scrap rate of the packaging line is climbing. Since waste is a mixture of cream and packaging materials, the only treatment is burying, which increases the cost of burying while reducing production.
Rewinds&J.Windsor (a distributor of Emerson CT drives) analyzed this issue and designed a solution based on a 6 servo drive. The key to the solution is to ensure precise synchronization between the drive itself and the chocolate ice cream line.
The solution selected six Emerson CT "MaxiMaestro" high-performance DC servo amplifiers for lane/crimp drive control, another amplifier for the package feeder, and a 7.5kW UnidriveSP for the jaw drive, onboard The SM application module provides full programming capability for the packaging machine, eliminating the need for a PLC to be used before.
“The key to this project is the capabilities of UnidriveSP,†explains MarketSwayne, project manager at Rewinds&J.Windsor. “We use the SM application module as a programming platform and use Emerson CT's SyPT programming software. This allows us to have the equivalent of a 3-level PLC, greatly simplifying the project without the need for a PLC, thus making the solution Extremely high price/performance ratio. Now we can adapt the system to any length of product with simple parameter adjustments, or digitally lock the entire system for precise synchronization."
Main advantage
Reduced scrap rate by 90%
Increase packaging line output
Saving production costs
Reduce waste disposal costs
Get faster project returns than expected
UNIDRIVESP has unique flexibility and connectivity
After the ice cream packaging machine is rebuilt, there will be no more waste caused by synchronous failure, and the overall scrap rate on the packaging line will be reduced by 90%. Due to the small amount of non-flat, the actual production of packaging lines has also been greatly improved. In addition, considering the cost savings in the production process and the cost of cutting waste, the project will receive faster returns than expected.