Stepwise Packaging Line Recipe Change With Incremental Retooling

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Solution Overview

Problem

Conventional packaging line operations require extensive downtime and material waste during recipe changes due to complete emptying and retooling, which is labor-intensive and time-consuming, relying heavily on operator expertise.

Innovation Solution

A step-by-step approach using a control device to automate process parameter adjustments and retooling at individual workstations along the packaging line, allowing seamless transition from one recipe to another without complete machine shutdown.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If complete emptying and retooling is performed for recipe change, then the packaging machine can be fully adapted to the new recipe, but material waste and downtime increase significantly

Engineering Contradiction:

Improverecipe adaptabilityVSAvoidmaterial waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The patent segments the retooling process into individual workstation-level operations rather than requiring complete line shutdown. Each workstation can be retooled independently while others continue operating, allowing recipe changes without complete emptying of the entire packaging line.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control device automatically prepares retooling parameters and notifications in advance before actual retooling begins. This preliminary automation reduces the need for manual intervention and material waste by precisely controlling when and how retooling occurs at each workstation.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If complete emptying and retooling is performed for recipe change, then the packaging machine can be fully adapted to the new recipe, but downtime increases significantly

Engineering Contradiction:

Improverecipe adaptabilityVSAvoiddowntime

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The packaging line is divided into multiple workstations that can operate independently. During recipe changes, only specific workstations need to be stopped for retooling while others continue production, significantly reducing overall downtime compared to complete line shutdown.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system maintains continuous production by allowing workstations to operate during retooling of other stations. The control device coordinates retooling operations to minimize disruption, ensuring that useful production action continues throughout the recipe change process.

Inventive Principle:

Principle #20Continuity of useful action

3Adaptability or versatility

If manual retooling measures are carried out by operating personnel, then recipe changes can be implemented, but labor intensity and operational complexity increase

Engineering Contradiction:

Improverecipe change capabilityVSAvoidoperator task complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The control device automatically manages many aspects of the recipe change process, including notifying operators of required retooling measures and coordinating timing. This self-service automation reduces the burden on operators and simplifies the overall recipe change operation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The control device provides feedback to operators about which retooling measures are needed and when they should be performed. This structured feedback system guides operators through the recipe change process, reducing complexity and the need for extensive operator expertise.

Inventive Principle:

Principle #23Feedback

4Productivity

If all workstations are retooled simultaneously, then the entire packaging line can produce the new recipe, but the retooling process becomes unmanageably complex

Engineering Contradiction:

Improverecipe change speedVSAvoidretooling process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The retooling process is segmented into individual workstation tasks rather than a single simultaneous operation. This segmentation makes the overall process more manageable by breaking it down into smaller, independently controllable units that can be executed in a coordinated sequence.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control device dynamically coordinates retooling operations across workstations based on real-time production needs. This dynamic approach allows flexible scheduling of retooling tasks, optimizing the balance between productivity and operational complexity rather than following a rigid simultaneous retooling schedule.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12534255B2Packaging machine or packaging line with dynamic recipe change

Publication Date: 2026.01.27 MULTIVAC SEPP HAGGENMULLER GMBH & CO KG

AI summary

The disclosure relates to a device for a packaging process, wherein the device is provided in the form of a step-by-step packaging machine, or is configured as a step-by-step packaging line. The device is configured to perform a recipe change from a first packaging recipe to another, second packaging recipe step by step at a plurality of work stations provided on the device. Furthermore, the disclosure relates to a corresponding method.