How to achieve sustainable manufacturing

SUSTAINABILITY in the packaging industry is one of the key aspects of fighting the plastic waste issue and ultimately climate change. The challenges that this presents, require flexible and powerful automation technology.

Holistic concepts are needed. Take coffee capsules, for example: On the one hand, consumers want a quick and easy way to prepare a fresh cup of coffee in the morning. On the other hand, the popular disposable capsules represent a huge environmental burden. New sustainable manufacturing approaches are the key.

Pillars of sustainable packaging

1. Reducing packaging material – not only in terms of virgin plastics content in primary packaging but also in the amount of protective secondary and final packaging. 
2. Eliminate the need for single-use packaging. Some strategies to tackle this issue start with increasing the use and scaling of reusable and refillable systems that are biodegradable, compostable, or have a lower impact on the environment if they end up in the landfill. Packaging made from mono materials is another strategy attracting increasing interest in the packaging industry. 

New requirements for production facilities

Shifting from rigid to flexible packaging reduces the amount of plastic, especially if it’s virgin. Thinner walls, smaller sizes, narrower seams, and lighter weights are good ways to reduce the amount of virgin plastic used in the primary container. Added to this is the use of nanomaterials, paper-based and biopolymers, as well as an increase in the proportion of recycled material in main packaging, protective and transport packaging (primary, secondary and final packaging).

Switch to new materials, ensure quality and safety

What is needed is future-proof manufacturing with automation and robotics technology that can work flexibly with different materials. The following examples show what companies should specifically look for:

1. Challenge film jamming

OMRON‘s Film Tension Control System provides synchronized control of tension, feed, and cut. This is complemented by (colour) mark detection for film compensation through motion control to ensure optimal unwinding of the roll. The OMROM Packaging Library offers a wide range of function blocks for film processing in VFFS machines.

2. Challenge film sealing

Thinner film materials offer lower costs and improved aesthetics. However, these materials are more sensitive to heat and susceptible to burning through when using traditional adhesives and sealing technologies. OMRON addresses this challenge with an AI-based temperature control algorithm synchronized with machine movement and sensor technology that can be placed closer to the sealing bar. Noise is compensated for by an automatic filter adjustment function.

3. Challenge quality control of packaging and label

Re-closable packaging or pouches with nozzles are increasingly replacing rigid plastic containers. More sustainable materials such as non-laminated or nanomaterials also change shape and can reduce the fidelity or performance of label printing. Reading, checking, or verifying label information on packaging is difficult when the shape is inconsistent, or the print quality changes. OMRON addresses this with its High-Speed Inspection System: this simple and scalable system is suitable for multiple lines and transparent integration with robotic systems. It offers a multi-camera platform with a single controller for multiple-image capture at high speed to reliably detect potential defects. Advanced algorithms help to detect difficult-to-read characters, in variable light conditions and high speeds.

4. Challenge new adhesives and gluing techniques

To produce and seal cartons, companies are increasingly relying on a strategic and reduced application of adhesives. This requires a high level of precision and continuous quality control. With its automated visual inspection system, OMRON supports the accurate detection of glue patterns. The high resolution and brightness settings allow low-contrast defects to be detected, even in the toughest light conditions or with difficult-to-detect materials.

5. Challenge of multi-material handling

OMRON offers a complete solution for sustainable packaging line automation that helps companies become more efficient and greener, utilizing their machines for new recyclable materials, and ensuring product quality. Sysmac is an integrated automation platform that provides complete control and management of the automation plant. At the core of this platform, the Machine Controller series supports synchronous control of all machine devices and offers advanced features such as motion, robotics, and database connectivity. This multidisciplinary concept allows simplification of the solution architecture, reduced programming effort, and optimized productivity. 

For inquiries about Omron Industrial Automation please contact: Omron Electronics (Pty) Ltd. Email: info.sa@omron.com Website: www.industrial.omron.co.za