The Best Packaging Quality, the Greatest Flexibility – and Minimum Operator Involvement
Wrap-around packer and wrap-around shrink packer round off the new Advanced series of packaging machines
Werner Ageling*
Werner Oster**
It's the product packaging that communicates with the consumer at the point of sale. If it's attractive, in an ideal situation it will persuade the consumer to buy. Badly packaged products, on the other hand, frequently remain unsellable. With this typical consumer behavior in mind, it thus seems all the more important for companies to attach great value to the quality of machines when investing in packaging technology. Another significant investment factor is choosing technical systems that are extremely flexible and also equipped to cope with future customer requirements. With its new Advanced series, KHS is able to provide the beverage, food, and non-food industries with packaging technology that takes the above criteria into account. The new Advanced series is a further development of the existing modular KHS packaging concept – with the modular aspect still a composite part. Depending on the demands made, the machines can be equipped with optimum functional modules in the low, medium, and high capacity ranges. If required, other modules, such as leaflet and partition inserters, can be integrated into the existing packaging machine or exchanged at a later date. Criteria pertaining to the new Advanced series have so far been implemented for shrink packers, tray packers, tray shrink packers, and pad shrink packers. The youngest members of the KHS Advanced family are the Innopack WP wrap-around packer and the Innopack WSP wrap-around shrink packer.
Capacity of up to 100 cycles per minute
Wrap-around packers and wrap-around shrink packers in the Advanced series are ideally suited for use in the beverage, food, and non-food industries. These packing machines are able to process an entire range of products manufactured by these sectors at capacities of 40 to 100 cycles per minute. Whether glass, metal, or plastic containers, cans, or cardboard cases – this new generation of machines packages them all perfectly. The individual containers may range in diameter from 48 to 120 millimeters and in height from 110 to 360 millimeters. Product group formations can be 160 to 540 millimeters long and 130 to 340 millimeters wide.
* Product Management Manager, Packaging Technology Competence Center,
KHS AG, Kleve. Phone: +49 (2821) 503-237
* Product Support Manager, Packaging Technology Competence Center,
KHS AG, Kleve. Phone: +49 (2821) 503-152
Processes a wide range of cardboard
Maximum flexibility is also provided with regard to the range of cardboard to be processed; wrap-around packers and wrap-around shrink packers in the new Advanced series can process various types of kraft and corrugated cardboard, from 0.6-millimeter kraft board to 5-millimeter corrugated cardboard.
Kraft cardboard boxes versus corrugated cardboard boxes
Kraft cardboard boxes usually have better humidity properties than corrugated cardboard packaging, making kraft cardboard boxes ideal for fridge packs. Fridge packs are wrap-around packaging made of kraft board – usually for cans and PET bottles – that on purchase normally go straight into the refrigerator, complete with the product inside. Fridge packs generally have a perforated section that can be torn open to allow easy access to the product. Fridge packs are especially popular in the U.S. and on the Latin American market. Kraft board's smooth surface also makes it perfect for use as wrap-around packaging, as advertising messages can be more easily printed onto it and the packaging thus more readily communicated to the consumer.
Corrugated cardboard boxes usually have thicker walls than their kraft board counterparts. Wrap-around packaging made of corrugated cardboard is thus often used for containers requiring increased protection, such as glass. Particularly in our modern age of globalization, deliveries the world over are no rare occurrence. Whether they are transported by sea, air, or truck, products are constantly exposed to potential damage. Suitably designed wrap-around packaging eliminates this risk, ensuring that packaged products have lost none of their appeal when they arrive at their destination. If products tend to be susceptible to a particularly large amount of impact, additional sections or partitions inserted into the wrap-around packaging can offer increased safety during transport. Corrugated cardboard wrap-around packaging usually has tear-off sections that can be opened in store, enabling consumers to quickly access the product safely contained in its wrap-around pack.
Optimum technical system plus perfect consultation services
Because the wrap-around packers and wrap-around shrink packers of the new Advanced series are able to process different types of cardboard, this means on the other hand that the customer may have trouble deciding which machine is best for the job. This is why in addition to supplying an optimized technical system, KHS offers pertinent advice on the packaging materials to be used. Consultancy services range from providing information on the type and strength of the cardboard for specific purposes to sharing knowledge regarding the box format, perforations, partitions, and so on and so forth. Before the selected materials go into production, test runs are usually carried out at the KHS plant. This ensures reliable processing from the very beginning. There is thus no question of investing in the wrong type of packaging material.
Tray and tray shrink packs are also feasible
The aspect of maximum flexibility is the central theme behind the new Advanced wrap-around packers and wrap-around shrink packers. The concept is especially convincing as each of the two packaging machines are able to produce both wrap-around and wrap-around shrink packs as well as tray and tray shrink packs. The only restriction is that the edge of the tray must be at least 40 millimeters high. This means that about 90% of all tray applications currently on the market can be processed by this new generation of machines.
Product grouping using multiservo sectioning units
When products are to be grouped into wrap-around packs, the products are fed to the wrap-around packers and wrap-around shrink packers according to the accumulation principle and split into lanes. The products are then grouped by a multiservo sectioning unit. This sectioning unit may use up to four servo motors depending on the requirements of the range of products to be processed to provide maximum flexibility and permit speeds of over 100 cycles per minute when creating product groups both big and small while ensuring extremely gentle product handling. The new multiservo sectioning unit has proved particularly advantageous when it comes to forming a number of product units with different sizes on one machine. This directly increases machine efficiency and also enables machinery positioned both upstream and downstream of the wrap-around packer or wrap-around shrink packer to run at full capacity at all times.
Identical servo motors with integrated servo controllers
Another plus for packaging concepts based on the new Advanced series of machines is that identical servo motors with integrated servo controllers are always used. Combining servo motors and servo controllers in one unit aids troubleshooting in the event of a fault as well as part replacement during maintenance. This in turn also cuts down on the necessary stock of spare parts. As the servo controllers are no longer housed in the switch cabinet – as has previously been the case – the amount of wiring is also greatly reduced. The switch cabinet can also be much smaller so that no cooling equipment is needed – except in tropical climates! This in turn helps to decrease the cost of electricity and maintenance.
Well thought-out blank feed, minimum operator involvement
The wrap-around and tray blanks are separated just below the grouping station. Cardboard blanks can be separated in a number of different ways. If blanks are supplied vertically from the magazine, they are picked up by a suction device which places them in the conveying chain in cycles. This method is used in particular by wrap-around packers and wrap-around shrink packers running at low to medium capacity. For high outputs it is imperative that the cardboard blanks be supplied horizontally from the magazine and that individual blanks are removed automatically by a belt system. Tried-and-tested special belts with a good-grip surface driven by a servo drive ensure that the blanks are perfectly indexed into the conveying chain. Optoelectronic sensors ensure highly reliable production throughout the entire cardboard blank conveying procedure. For high-performance machines in particular, it is possible to magazine over 2,000 cardboard blanks on a conveyor installed upstream of the blank separating unit. An automatic loader feeds the stored blanks to the blank separating unit. With a wrap-around packer or wrap-around shrink packer running at a maximum speed of 100 cycles a minute with 2,000 stored blanks, the machine can run unattended for 20 minutes. If the machine is to run entirely unattended in this area, the blanks can also be loaded onto the conveyor belt by robot.
Product groups are held firmly in place and safely conveyed at all times
Whether the blanks are to be extracted by suction or by a belt system, they are always indexed to the drag chain with the utmost precision so that they coincide with the arrival of the product groups formed in the grouping station. The special feature of this packaging system is that the products are always held firmly in place. There is no risk of containers missing in the box. This is guaranteed by folding chains equipped with special cam-controlled, folding pickups. As soon as a product group enters the blank, one of the folding pickups makes sure that the front of the wrap-around cardboard blank is folded up. At the same time, the products at the back of the formation are held securely by a rod. Once the product formation has been perfectly positioned on the blank, a second folding pickup closes up the rear section of the cardboard blank. Special folding cams gently lift both sides of the blanks while the blanks and product group are being combined.
The flexible action of the cam-controlled folding pickups reopens the front and rear of each blank slightly as soon as the product formation has been fed into the blank so that the gluing tab can be folded in correctly. Glue is then applied by special hot melt application heads and the front and rear sections of the wrap-around pack are finally closed at a 90° angle. The next step in the procedure is to fold and glue the lid flap. The wrap-around pack is formed and glued and now runs through the application pressure segment.
The products are always guided securely through the process described above. This is vitally important especially when processing wrap-around packaging. For once a wrap-around box has been sealed, it is no longer possible to see if it really contains the specified number of products. It would only be possible to verify this by weighing the pack, which would not only take more time and effort but also increase the cost of investment.
Broadside first or lengthwise? Both options possible for tray packs
In addition to producing wrap-around packs, wrap-around packers and wrap-around shrink packers are also able to package products in trays and tray shrink packs. There are two possible processing options here. The first entails cardboard tray blanks and wrap-around blanks being fed into the machine narrow side first. In this case, the same tray blanks used in tray packers and tray shrink packers are also suitable for wrap-around packers and wrap-around shrink packers. The second permits tray blanks specially designed for wrap-around packers and wrap-around shrink packers to be processed broadside first.
The "broadside first" method is of an especial advantage when trays loaded with product are to be shrink wrapped. The tray packs are sent broadside first straight to the shrink wrapper. If it arrives long side first, the tray pack has to be turned before it is passed on to the film station. This makes the integration of an additional turning station in the machine concept necessary, increasing the amount of space and time required as opposed to the classic system. This setup also has several advantages when it comes to feeding pre-packed products. Six-packs wrapped in film and produced on an upstream shrink packer do not have to be turned before they reach the wrap-around packer, for example.
A process similar to producing wrap-around packs is applied when tray packs are created on wrap-around packers and wrap-around shrink packers. Here, however, the upper binding segment is not required and folding tools and hot melt nozzles are positioned so that they match tray parameters.
Fast format changeover
The fast format changeover integrated in the Advanced concept assists the speedy conversion of packaging technology from tray and tray shrink packs to wrap-around and wrap-around shrink packs (or vice versa). Operators can choose between an automatic and an operator-controlled version. The advantage of operator-controlled format changeover is that the operator panel informs the machine operator exactly where new settings have to be made. At the same time, with operator controlled format changeover using electronic display, information on how to adjust the machine at individual stations is accurately communicated. Any play in the gear wheels or chains is already taken into account with the relevant instructions – yet another plus point. With operator prompted format changeover, adjustments can optionally be made either manually or by means of Accu-Drive. Adjusting the folding station in the direction of travel is also new and will in the future be possible by simply selecting the format on the control panel. The servo motors adjust the folding and applicator chains to the new gaps for other formations practically at the push of a button.
Film wrapping module with many special features
The only difference between the wrap-around packer and the wrap-around shrink packer in the Advanced series is that in the latter system, a film wrapping module has been included and a shrink tunnel connected up directly downstream of the film wrapping unit. Besides film wrapping individual tray packs and individual wrap-around packs, the wrap-around shrink packer is also able to wrap several wrap-around packaging units in plastic film. This is useful if, for example, the palletizer does not have sufficient capacity to process small, separate wrap-around packs or if high-quality printing on groups of wrap-around packs is to be given special protection. A grouping station is integrated into the system ahead of the film wrapping unit to enable 'multiple' packaging, where a stacking module can be included in the concept to stack two trays prior to film wrapping. This also helps to reduce packaging material consumption and cut down on palletizer speed requirements.
Processing of extremely thin film possible
The Advanced series also has a few novelties up its sleeve when it comes to the film wrapping process. Here, the system can handle much thinner and much wider film than has previously been possible. Perfect processing results are guaranteed with films of up to 35 µm in thickness and 950 mm in width. Working continuously, the film station regulates movement by means of an electronic cam. The length of film section and position of the printed image are electronically set in the system by selecting the format at the operator panel. A servo-driven film cutter cuts the plastic film exactly. The new Advanced series also allows integration of an optional end-of-film-reel check. An electrostatic sensor detects the perforation that has been stamped into the film especially for this purpose. The machine is then automatically stopped so that the film reel can be changed. An average of 0.8 kilograms of film material is saved per reel – real cash savings.
ECO shrink tunnel uses less energy and reduces CO2 emissions
Money can also be saved by using what is known as the ECO shrink tunnel placed downstream of the film wrapping module. This operates with a gas heater instead of the electric heater used in the classic shrink tunnel. The ECO shrink tunnel concept lives up to its name mainly in that it uses up to 50% less energy versus the conventional type of shrink tunnel. The environment also benefits from a considerable reduction in CO2 emissions.
The versatile complete concept
Packaging systems in the Advanced series are distinguished by the fact that the technology can be customized to suit individual requirements by simply integrating various functional modules. It is possible to extend the existing packaging engineering of Advance series wrap-around packers and wrap-around shrink packers by simply adding on modules. It is also possible, on the other hand, to remove functional modules that are no longer required from the system. This shows just how versatile the Advanced series concept is in every respect. It would be feasible, for example, to integrate a partition inserter into the machine concept. This module for wrap-around packs is particularly useful for products that are to be shipped long distances and require extra special protection. The partition inserter is positioned directly above the conveyors transporting the packaging to be processed. The system therefore does not take up any additional space.
Cubic machine frame for maximum ease of operation
Another major advantage of the Advanced series is the cubic design of the machine frame. For single-lane wrap-around packers and wrap-around shrink packers, the plus of this type of construction lies in the increased ease of operation. The cubic machine design thus creates more space within the machine. The protective hoods also provide an excellent view into the machine during production. In addition, the swing-up protective hoods are easier for operators to open and close, allowing optimum access to all parts of the machine.
An even greater all-rounder for the future?
The new Advanced wrap-around packer and wrap-around shrink packer already cover a wide spectrum of applications, producing wrap-around packs, wrap-around shrink packs, tray packs, and tray shrink packs. This spectrum could even be broadened in the future. KHS is currently testing if additional processing of pad shrink packs and just shrink packs would be possible on this setup. That would mean that the wrap-around packers and wrap-around shrink packers in the Advanced series could be marketed as even greater all-round talents. But perhaps the most persuasive argument of all is that thanks to the modular system, all Advanced packaging systems currently on the market will also directly profit from these new opportunities in the future.
