Composite Package Filling Plant With Auto Parameter Setup
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Solution Overview
Problem
Existing filling plants for packaging pourable food products into composite packages face inefficiencies in parameter setting, requiring manual intervention by trained operators, which can be time-consuming and prone to errors, and often result in delayed or incorrect settings during product or package format changes.
Innovation Solution
A filling plant equipped with a control device that reads identification codes on the packaging material to automatically set operational parameters, including quality control protocols and hygiene measures, reducing the need for manual intervention and ensuring accurate, timely adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual parameter setting by technical operators is used, then operational flexibility and adaptability are maintained, but time consumption increases and error probability rises
Solution Approach 1:
The system stores pre-configured parameter sets in a database, each associated with specific packaging material types and product characteristics. When a production cycle begins, the system automatically retrieves and applies the appropriate pre-stored parameter set, eliminating the need for manual parameter entry and reducing setup time while maintaining operational flexibility.
Solution Approach 2:
The filling plant's control system automatically determines which parameter set to apply based on identification data from the packaging material (such as barcode or RFID tags). The system self-configures by retrieving the correct parameters from its database and applying them without human intervention, thereby reducing both time consumption and error probability.
2Ease of operation
If manual parameter setting by technical operators is used, then operational flexibility is maintained, but accuracy and reliability of parameter setting deteriorate
Solution Approach 1:
The system incorporates a feedback mechanism where the control unit reads identification data from the packaging material, automatically queries the database for the corresponding parameter set, and applies it. This closed-loop approach ensures that the correct parameters are consistently applied based on the actual material being processed, eliminating human error while maintaining operational flexibility.
Solution Approach 2:
The manual mechanical process of parameter setting by operators is replaced with an automated electronic control system. The system uses electronic data retrieval and automatic parameter application, substituting human judgment and manual input with automated digital processes, thereby improving reliability and accuracy.
3Productivity
If automated parameter setting based on identification codes is implemented, then productivity and accuracy are improved, but device complexity increases
Solution Approach 1:
The control system is designed to be universal, handling multiple packaging material types, product varieties, and parameter configurations through a single integrated database and control unit. This multi-functional approach allows the system to automatically adapt to different production scenarios without requiring separate control mechanisms for each case, thereby limiting the increase in complexity while maintaining high productivity.
Solution Approach 2:
The system manages complexity by organizing parameters into structured sets that can be easily stored, retrieved, and applied. Each parameter set is associated with specific identification codes, allowing the system to switch between different configurations by simply changing which parameter set is active, rather than managing individual parameters separately. This approach enables rapid parameter changes while keeping the control structure manageable.
Data Source
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AI summary
There is described a filling plant (1) for filling pourable food products into composite packages (2). The filling plant (1) is configured to form the composite packages (2) from a multilayer composite packaging material (3) and to fill the composite packages (2) with the pourable food product. The filling plant (1) comprises at least a control device (5) configured to control operation of the filling plant (1) and an input device operatively connected to the control device (5) and configured to receive an identification code (7) indicative of the specific multilayer composite packaging material (3) and/or the composite packages (2) and/or the pourable product to be filled and to send a signal about the identification code (7) to the control device (5). The control device (5) is configured to set operational parameters of the filling plant (1) as a function of the identification code (7).