Ask an EngineerAutomated changeovers help bagging systems keep pace with packaging variability
By Ryan Klemetson on September 7, 2021
Packaging manufacturers face increasing pressure to run more products, more package sizes and shorter production runs, all while maintaining throughput and quality. One machine builder overcame these challenges by combining smart mechanical design with the flexibility and precision of Tolomatic electric actuators.
Design flexibility solves packaging problem
Speed, repeatability and flexibility are critical to the success of modern packaging operations. Today’s manufacturers are expected to process a wider variety of products and packaging formats while minimizing downtime between production runs.
For builders of automated bagging systems, this creates a unique challenge. Even small variations in bag dimensions can affect package quality, increase product waste and slow overall production. At the same time, customers expect equipment that can adapt quickly to changing product requirements without extensive manual adjustments.
One packaging machine manufacturer serving bulk-material processing industries encountered this exact challenge. Their modular bag-filling and sealing systems are used to package products ranging from pet food and animal feed to sugar, salt, fertilizer, seed and soil products.
The equipment accurately measures, fills and seals bags, but growing variability in packaging materials created a new obstacle.
Packaging variability creates production challenges
Historically, customers used premium bags with highly consistent dimensions. A simple adjustment at the beginning of a production run was enough to maintain reliable operation.
As more manufacturers sought cost-effective packaging materials, however, bag dimensional variability increased significantly. Some bags varied in length by as much as three-quarters of an inch. That variation created positioning issues at the bag staging area where empty bags are presented to the filling line. If a bag was not positioned correctly, filling and sealing performance could suffer, leading to rejected packages, waste and reduced throughput.
The machine builder needed a solution that would automatically compensate for dimensional differences while supporting fast changeovers between bag sizes.
Flexible electric motion eliminates manual adjustments
Working with Tolomatic engineers, the machine builder developed a bag-top reference mechanism that automatically aligns bags regardless of dimensional variation.
The system uses four modified Tolomatic B3S rodless electric screw actuators to precisely position incoming bags before they enter the filling and sealing process.
Rather than relying on manual adjustments, the actuators automatically reposition each bag to a precise reference location. The result is consistent presentation of bags to downstream operations, even when bag dimensions vary from package to package.
This automated approach not only improves accuracy but also helps operators transition more quickly between production runs.
Designed for fast changeovers
In today’s packaging environment, machine flexibility extends far beyond handling dimensional variation. Manufacturers frequently change bag sizes, product types and production schedules throughout the day.
The Tolomatic actuator solution allows operators to select pre-programmed positioning parameters rather than manually adjusting mechanical components.
By incorporating programmable motion into the machine design, the builder reduced setup time, simplified changeovers and improved repeatability between batches.
The result is a system capable of supporting modern packaging requirements, including:
- Greater SKU variety
- More frequent product changeovers
- Reduced operator intervention
- Consistent machine setup
- Improved production efficiency
For packaging operations focused on maximizing uptime, automated adjustment capabilities can significantly reduce non-productive time between runs.
How the system works
Two vertically mounted electric actuators adjust bag position based on feedback from an inspection system. As bags are loaded into staging trays, the actuators lower each bag to a precise reference point.
Simultaneously, two horizontally mounted B3S actuators center each bag within the tray.
The horizontal actuators feature multiple carriers operating on a single screw mechanism. As the screw rotates, the carriers move toward one another, automatically centering the bag before it enters the filling process.
Once properly aligned, the bags are transferred into the filling and sealing line.
The automated positioning process ensures repeatable bag presentation across a wide range of bag dimensions without sacrificing speed or accuracy
Built for demanding packaging environments
Packaging systems often operate in harsh conditions, particularly when handling products such as salt, fertilizer, seed or soil.
The B3S actuator’s enclosed design helps protect internal components from dust, debris and contaminants. A stainless-steel sealing band shields critical motion components while supporting long-term reliability and reduced maintenance requirements.
This rugged design allows machine builders to implement precise electric motion in environments where durability is just as important as performance.
Improving overall equipment effectiveness
Beyond solving the immediate bag-positioning challenge, the actuator-based design delivered broader operational benefits.
By automating adjustments and compensating for bag variation, the machine builder improved:
- Repeatability
- Package quality
- Changeover efficiency
- Production consistency
- Operator productivity
The design maintains positioning tolerances of ±0.031 inches while handling a wide range of bag sizes. This level of precision helps reduce filling and sealing issues while supporting higher overall equipment effectiveness (OEE).
Flexible solutions for packaging machine builders
Packaging OEMs increasingly need motion solutions that can adapt to changing customer requirements without requiring extensive customization or redesign.
Tolomatic electric actuators offer multiple mounting, motor and drive configuration options and integrate easily with a wide variety of industry-standard servo systems and PLC platforms. This flexibility allows machine builders to develop highly adaptable equipment while simplifying implementation and commissioning.
Whether the application involves bag positioning, automated format adjustment, conveying, indexing or other packaging machine functions, electric actuators provide the precision, repeatability and flexibility needed to support modern automation goals.
Keep your packaging equipment ready for what’s next
Packaging demands continue to evolve. More product variation, faster changeovers and increasing quality expectations require machines that can automatically adapt without sacrificing throughput.
By combining thoughtful machine design with Tolomatic electric actuator technology, this packaging OEM transformed a manual adjustment process into an automated, repeatable solution that improves productivity and supports long-term operational flexibility. Read the full story here.
Thinking about switching from pneumatic cylinders to electric actuators? Download our white paper comparing the two technologies.
Designing packaging equipment that requires accurate positioning, automated adjustments or rapid changeovers? Contact a Tolomatic engineer to discuss the right electric motion solution for your application.