IEN: What are the major concerns facing automation, and how can they be addressed?
Ellis: The latest trend in automated packaging is a significant shift toward custom-engineered solutions that focus on high-accuracy counting and packaging with very low changeover times. The current market for custom solutions is approximately 20%, where it used to be 5-8%. These custom-engineered packaging systems have improved accuracy with custom infeeds designed for specific applications. In the 80s and 90s, an overcount of 10% was acceptable in exchange for higher productivity of 15-20 bags per minute. With today''s higher cost components and tighter profit margins, a 10% overcount is no longer acceptable. Today''s high-accuracy packaging systems are engineered to yield less than 2% overcounts at speeds of 30 bags per minute.
IEN: What innovations are in store in software, systems, intelligent field devices, digital manufacturing, customization, optimization, and other areas?
Ellis: The biggest improvement in overall system throughput has been related to computing power and software enhancements that allow counter settings, bag settings, and label information to be stored as a single job. All system parameters related to a saved job are stored as a single setup, which means job changeovers can be accomplished in less than three minutes average. A new AutoTouch control screen for Autobag packaging systems reduces setup time by controlling operations for the bagger, printer, and eventually, infeeds. This reduces total setup time by one hour per day, which can yield up to 1,500-2,000 more packages per shift.
IEN: What are the R & D hotspots, and which R & D areas are closest to commercialization?
Ellis: In the next 10 years we expect quality control to continue to be an area of advanced technology development. RFID is rapidly evolving into a cost-effective content verification tool. Some medical applications for RFID already exist and this will expand into other markets. In fact, Automated Packaging Systems will be demonstrating a next-generation RFID Validation System in its booth at Pack Expo this fall.
IEN: Can 24/7 preventive or predictive monitoring be assured in Ethernet-based systems?
Ellis: Yes, and Automated Packaging Systems is driving technology to utilize a supervisory PC to monitor productivity, diagnostics, uptime, and other operating parameters. Ultimately, as the market demands, this information could be integrated into a company-wide network for remote monitoring and analysis. Factory service engineers have instant access to data stored in the system and can download data into their own PCs. An error-log screen quickly identifies fault conditions and jobs run, which provides the operator with useful diagnostic information. Sometimes, a simple call to the service engineer can identify a problem even before a visit is required.
IEN: What advances do you see in production management, collaborative manufacturing, plant intelligence and visibility, advanced process control?
Ellis: The biggest advancements in production management will be related to software and firmware upgrades to allow packaging systems to be fully integrated with a company-wide network. Remote monitoring and analysis will become standard operating procedures. Automated Packaging Systems is already offering free upgrades to those customers that have signed up for the Autobag Systems Advantage Program.
It''s like getting a new PC with free software and firmware upgrades for the life of the machine. New product enhancements are coming out all the time and the most progressive companies are now providing long-term value to their customers by ensuring their systems will remain current for many years. Automated Packaging utilizes a centralized, modular design control "E-box" that can be easily replaced and exchanged on a "repair and return" program. This along with easy access, "plug-and-play" components allows for maximum uptime.