Advanced Retrofit for High-Mix Carton Filling and Packaging Lines
Challenge
A third-party manufacturer in the cosmetics and pharmaceutical sectors struggled to manage production due to technologically outdated packaging machines.
The box handling system suffered from rigid mechanics that made format changeovers lengthy and complex, leading to frequent machine downtime.
The lack of modern electronic control prevented the synchronization necessary to manage boxes of different sizes, resulting in a high rate of cardboard waste and damaged products.
IEMA US Intervention
- Packaging Machine Retrofit: Integration of brushless motors and servo drives to replace old mechanical cams, ensuring complete flexibility in format changeovers.
- Machine Upgrade: Replacement of obsolete PLCs with Rockwell ControlLogix or Siemens S7 architectures for precise and fast control of filling cycles.
- System Renewal: Implementation of new management software with pre-set recipes to instantly switch between different box types (cosmetics, vials, blisters).
- Advanced Monitoring: Installation of intelligent sensors for quality control and box defect identification before final sealing.
The Results
- Format changeovers reduced by 80% thanks to digital recipe management and flexible servomotors.
- 30% reduction in overall packaging line downtime.
- Elimination of packaging waste resulting from mechanical jams or synchronization errors.
- Full UL compliance and data traceability ready for Industry 4.0 integration.
Want to explore the benefits of industrial revamping?
-
Download our PDF brochure to discover:
-
The real advantages of revamping and renewing
-
Real-world case studies
-
Technologies used and results achieved
Have questions? Get in touch—our team is here to help