Trajexia packs 50,000 bottles per hour

When a Russian customer decided to build new packaging equipment for bottle wrapping they had 3 key requirements: 50,000 bottle/hr throughput, longer machine availability and system flexibility to wrap various package sizes. With over 30 years experience in packaging systems, Novopac and Ci.ti.emme, were selected to design the new packaging line.

It was clear to both companies that the complete production process had to be continuous. Hence fully synchronized multiaxis motion control was a must. To achieve that Trajexia platform offered the best option.

The wrapping process

Fed randomly from a conveyor, the bottles are spaced, aligned and then fed in packs of 20 in full synchronization on the packaging tray. This complex task is performed by a 2-axis arm driven by two 850 W servodrives synchronized through a Cambox function. In order to avoid any collision at emergency stop the motors use absolute encoders. A third axis, driven by an 850 W servomotor and synchronized with the bottle tray, feeds a carton sheet underneath the packed bottles.

A forth axis, driven by a 2900 W motor, unwinds the wrapping film over the bottles performing a Cambox function. Finally a fifth axis driven by a 850 W motor cuts the film using a Movelink function. All axes are slaved to the master conveyor, which is driven by a 2900 W motor.

The motion-control system

Trajexia’s complete and integrated platform was chosen to handle the whole wrapping process. The TJ1 motion-control unit driving all 6 axes over the Mechatrolink II motion bus performed all complex motion tasks through simple and intuitive motion basic commands such as Cambox, Movelink and Connect commands.

The machine management, safety interlocks and operator interface tasks are performed by a CJ1 PLC and an NS8 terminal.

Modular, flexible and robust

The use of electronic synchronization allowed huge flexibility and adaptability of the machine to satisfy customer demands for various packing sizes and production rates. It is more compact and also easier to maintain thanks to the transparent communications down to the servo level. The clear separation between motion tasks and sequencing tasks also gave the machine builder greater flexibility to use other PLC brands if the end customer so wishes.

Job well done

Thanks to the ease of use and the plug & work concept of Trajexia platform, the new production line was built and commissioned within schedule. Omron’s fully integrated platform helps full operation at desired performance, with highest reliability. Also local or remote interaction with all devices on the machine allows full teleservicing. Trajexia makes motion easy.