Filling machine electrically driven for increased output

Sydney-based packaging machinery company, Packserv Australia, developed a new-generation filling machine, designed to boost productivity, precision and efficiency. The electronically driven machine included added features and functionality by incorporating components from SMC Corporation’s range of digital Industry 4.0 enabled components. By incorporating electrical automation, the filling machine delivers real-time data and metrics, with the added capability of incorporating artificial intelligence (AI) and machine learning.

Nathan Wardell, Managing Director of Packserv, said: “We have looked to SMC for its range of pneumatic components, and we still do, but this machine required digital, PLC controlled electric actuators. This shift that has opened a world of possibilities that aren’t available in machines making use of pneumatics.”

The key reason for the development of this machine is underpinned by increased output.

“By switching to electric actuators and expanding the machine to include eight heads and twin-lane functionality, our clients are able to significantly increase the output of the machine,” Wardell said. “We are also working on additional new machines of the same ilk to add to our new range of production lines.”

“Bringing electrical automation to the fore means that we can now fill around 100 units per minute or more — depending on the product, size and variable factors such as froth and foam.

“The indexing of containers can take a while post-fill, so we introduced a second lane to ensure that we could meet our clients’ output requirements of more than 100 units per minute,” Wardell said.

Capping off the project

Packserv looked to SMC’s electric actuator range to help bolster its fillers and cappers production capabilities. The companies have worked together for 17 years and Wardell has nearly 30 years of working experience with SMC.

Reflecting on the early days of this project, Mikael Sandell, Key Account Manager for SMC Corporation, said that he was excited to bring the benefits of electric actuators to Packserv, noting that it was the “perfect fit for the brief”.

“When it comes to extreme accuracy, speed control and positioning, the electric servo motor ball screw and belt actuators from SMC are the ideal solution,” Sandell said.

According to Wardell, the speed of the fill is increased and reduced in three stages. As the product enters, it is filled at 30% because of bubbling and frothing; it is then sped up to 100% mid stroke and speed is reduced to 30% in the narrowing of the neck so that it doesn’t overfill the container.

Beyond the precision that electric actuators provide, the drives are also used to monitor the machine — from both near and far — providing real-time feedback, data and metrics. In addition, preventive maintenance and technical support can save downtime for users.

SMC specified the LE series servo drive for this project. “They can be configured to suit each individual filling process with speed, torque and position control. They communicate with the fastest Industrial Ethernet technology providing real-time control and feedback,” Sandell said.

He added that while “pneumatic solutions still most certainly have their place in the market”, this application called for electrical components which SMC was able to provide with its range.

“This is our first prototype of its kind, and it was well received at APPEX 2024,” Wardell said. “We are excited to see where the future takes us.”

Image credit: Packserv Australia.