Digitally Controlled Packaging Line for Individualized Print and Cut

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Solution Overview

Problem

Conventional package manufacturing processes, particularly in the pharmaceutical industry, face challenges in producing individualized packages efficiently and safely, with limitations in handling small series and high variability, leading to inefficiencies and safety concerns due to the need for separate machines and manual handling.

Innovation Solution

Implementing a digitally controlled manufacturing line with modular components that allow for precise digital control and communication across stages, enabling individualized printing, cutting, and processing without intermediate manual phases or separate material handling, thus facilitating flexible production and improved traceability and authentication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional offset printing technology is used for package manufacturing, then uniform and high print quality is achieved, but individualization of packages and small series production become difficult or impossible

Engineering Contradiction:

Improveprint qualityVSAvoidindividualization capability

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The printing process is segmented into multiple independent printing units (first printing unit, second printing unit, third printing unit) that can operate independently. Each unit can apply different printing methods (offset printing for standard content, digital printing for variable data) to different portions of the package, enabling both high quality and individualization.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent merges conventional offset printing technology with digital printing technology in a single integrated manufacturing line. The offset printing units provide high-quality base printing, while digital printing units add variable individualized data, combining the advantages of both methods into one system.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If separate machines and manual handling are used for individualized packages, then individualization is achieved, but production efficiency decreases and downtime increases

Engineering Contradiction:

Improveindividualization capabilityVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Multiple printing units and processing stages are merged into a single continuous manufacturing line. Packages move through the line without manual intervention, with each unit performing its function in sequence, maintaining high speed and efficiency while achieving individualization.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The manufacturing process operates continuously with packages moving through all printing and processing units in an unbroken sequence. There are no manual handling phases or interruptions between units, ensuring continuous productive action throughout the entire individualization process.

Inventive Principle:

Principle #20Continuity of useful action

3Adaptability or versatility

If package types are changed during production, then product versatility is improved, but machine emptying and material removal cause downtime and reduce effectiveness

Engineering Contradiction:

Improveproduct varietyVSAvoiddowntime

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

A control system monitors the manufacturing process and receives information about package types and printing content. When a change in package type is detected or anticipated, the control system automatically adjusts the printing units and prepares for the next product type, enabling quick transitions without manual machine emptying.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The printing system is designed to be dynamically adjustable, with digital printing units that can change their output content electronically without physical reconfiguration. This allows the system to adapt to different package types and individualization requirements on-the-fly, minimizing downtime during product changes.

Inventive Principle:

Principle #15Dynamics

4Adaptability or versatility

If modular digitally controlled components are implemented, then flexibility and traceability are improved, but system complexity increases

Engineering Contradiction:

Improveproduction flexibilityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The manufacturing system is divided into distinct modular units (separate printing units, control modules, and processing stages), each with a specific function. This segmentation allows for independent control and monitoring of each module, making the complex system manageable through standardized interfaces and reducing overall system complexity.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP2268479B1Method and arrangement for manufacturing packages in a digitally controlled process

Publication Date: 2017.06.14 TRESU

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AI summary

Packages are manufactured in a digitally controlled process. A digital printing machine (101) produces printed workpieces and a cutting machine (104) cuts packaging blanks (105) from them. A conveyor line (107) transfers the printed workpieces automatically from the digital printing machine (101) to the cutting machine (104). A digital control system (109) exchanges digital control information with at least the digital printing machine (101) and the cutting machine (104).