PACKAGING TECHNOLOGY: Lines and Equipment, Data Tracking and Acquisition, Weighing Applications and More...

CONTACT: Leonard B. Antosiak - Pharmaceutical Production TechSourceŽ - P.O. Box 1145 -
Ann Arbor, MI 48106-1145 - (Telephone: 734.528.0444) - (eMail: ppt@2020comm.net) - (WEB PAGE: http://PharmaceuticalProductionTechSource.com)

PACKAGING TECHNOLOGY: Lines and Equipment, Data Tracking and Acquisition, Weighing Applications and More...

PACKAGING TECHNOLOGY: for Lines and Equipment, Data Tracking and Acquisition,
Weighing Applications and More...
(Technology that will improve your lines and your equipment! Great applications for pharmaceutical, beverage and similar industries.)

The following technology is addressed on this page: - Adjustable "Machine Height" Movement and Monitoring - Adjustable "Machine Height" Movement and Monitoring on a Krones Labeler: Case History - Downtime Tracking System to Help Keep Track of OEE - Status Boards and Software For Real Time Data Collection and Feedback Helps to Ensure a Smooth Running Line - Automation Software with Signature Analysis - Hand-Held Data Acquisition with Signature - I/O Weigh Scale Modules for Package Weighing Application Case Histories - Safety Light Curtains - Weigh Module Applications - Weighing Load Cells and Applications

Cost-effective and uncomplicated technology can be easily applied to your packaging operation! This will improve your through-put rates, product quality and help protect your equipment.

You can achieve vertical startups and drastically reduce or eliminate your startup/debugging times by accurately monitoring and controlling your equipment's vertical and horizontal movements. You will reduce your material losses, scraped product and save money. It is well suited for everything from carton erectors, labeling equipment, case packers and more....

Adjustable "Machine Height" Movement and Monitoring
LDT/Shut-Height Technology and Components for Packaging Lines, Equipment, etc...

Even though this technology is referred to as "machine height", it can be applied to both vertical and horizontal adjustable movements/set-points. Adjustments are based on Allen Bradley (AB) PLC controllers to accurately monitor, and control motor driven machine adjustments. Precision linear transducers are mounted onto the machine, to measure adjustments to within .005" accuracy. The adjustment value is displayed with the ability to store, and recall target settings for multiple jobs. Control output relays interface to the machine adjustment motors, to initiate automatic, and corrected adjustments for the desired job run. Stand-Alone (SA) and Allen-Bradley PLC integrated versions are available in both 4 and 8 channel packages. This technology can provide both vertical and horizontal adjustments, it's a very robust application!

Specifications for Installation: these units are simple to install and operate, and provide great time savings over manual methods when a job changeover is required for different products or sizes:

Transducer input voltage: 7 - 30 VDC

Transducer currrent: 40 ma @ 24 VDC

Transducer output: analog, 0 - 10 VDC

Measurement repeatablility: ą.001"

Measurement accuracy: ą.005"

Temperature range: 32° to 140° F

"Stand Alone" Adjustable Machine Height Monitor Technology: this unit contains proven and reliable Allen Bradley PLC based electronics. It can have either 4 or 8 channels of machine height monitoring and related circuitry, with the ability to accept 0 to 10 VDC analog input signals from 1 to 4, or, 1 to 8 linear displacement transducers (LDT's). It displays the actual machine adjustment set-points, and can store them for multiple jobs. When a new job is entered, it provides the proper up/down, or, left/right machine adjustment output signals. The system's measurement accuracy and display resolution is within .005" (note: actual machine adjustment accuracy is dependent upon the condition of the height adjust drive and machine's condition). An integral compact color touch screen display (4" diagonal) contains the following functions:

Entering setup and calibration values for the linear displacement transducers

Show the actual "machine adjustments" for all connected transducers

Enter and display the proper LDT machine adjustment values for particular jobs based upon the assigned "job numbers"

Contains up/down "pushbotton" function on display to manually adjust machine set-points

Store, recall and activate up to 100 different "job based" machine adjustments for the connected transducers (note: each LDT will have its own unique job machine set-points)

120 VAC control voltage up/down outputs to provide the proper control signals to the machine height motorized actuators (note: when a new job is entered and activated, the actuators will atuomatically adjust the machine set-points as needed)

Ability to disable the unused channels

Password protection to limit machine adjustments only to authorized personnel

Unit configured for 120 VAC external power

All items factory wired and housed in gasketed sealed NEMA 4x stainless steel enclosure for "washdown" protection and corrosion resistance

Machine height motorized actuators are not furnished

Unit options include a "remote job activation" freature to remotely activate a new job with the proper settings from a "panel view" operator interface at the main machine control

"PLC Integrated" Adjustable Machine Height Monitor Technology: this unit can interface to existing Allen Bradley PLC and panel view displays in the main machine control AB Micrologix/Compactlogix, SLC-500 and ControlLogix platforms. It can be utilized with 4 or 8 channels of machine adjustment monitoring and related hardware, with the ability to accept 0 to 10 VDC analog input signals from 1 to 4, or, 1 to 8 linear displacement transducers (LDT's). The actual machine adjustments are displayed from the connected LDT's, and it stores the proper machine heights for multiple jobs. When a new job is entered, the proper up/down, or, left/right machine adjustment output signal is provided. The system's measurement accuracy and display resolution is within .005" (note: actual machine adjustment accuracy is dependent upon the condition of the height adjust drive and machine's condition). Hardware consists of AB PLC analog input modules for installation in the open slots of the existing PLC control rack. Engineering/programming for the existing machine's AB PLC control and panel view display is needed to attain the following functions:

Entering setup and calibration values for the linear displacement transducers

Shows the actual "machine adjustments" for all connected transducers

Enters and displays the proper LDT machine adjustment values for particular jobs based upon the assigned "job numbers"

Stores, recalls and activates up to 100 different "job based" machine adjustmentss for the connected transducers (note: each LDT will have its own unique job machine set-point)

Ability to provide the proper control signals to the existing machine adjustment motorized actuators with existing contactors (note: when a new job is entered and activated, the actuators will automatically adjust the machine as needed)

Ability to disable the unused channels

Password protection to limit machine adjustments only to authorized personnel

Machine height motorized actuators are not furnished. The customer will need to provide the existing PLC control program, and the panel view display program so the interface programming work can be completed. Confidential nondisclosure agreements can be signed as needed.

"Linear Displacement Transducer (LDT)" Machine Height Monitor Technology: the "standard duty" transducer Model H-LDT-SD-XXXX ("XXXX" designates active sensing length in inches, "0120" to 12.0" in length), with sensing lengths from 12.0" to 60.0" in .1" increments. Standard transducer features include the following:

Mounting on motorized adjustable machine support legs to provide a calibrated output signal for the machine's height

Can be mounted for vertical (height) or horizontal machine adjustment

Provides a 0 to 10 VDC analog output signal

Rugged construction for industrial applications

Stainless steel sensing tube

Electronics enclosed in aluminum housing with O-ring seals, with IP67 rating for dust and water protection

Hard wired 30' cable with cordgrip fittings at cable exit (note: longer cable lenghts are available upon request)

Sensor magnet ring

Adjustable steel mounting brackets for sensor unit (stationary machine section) and for magnet ring (moving adjustable machine section)

Transducer options include "heavy duty" stainless steel transducer (Model H-LDT-HD-XXXX), with stainless steel sensing tube and stainless steel electronics enclosure with O-ring seals for washdown protection from caustic cleaning agents; included are stainless steel mounting brackets for sensor unit and magnet ring with a long-length cable of over 30'

Adjustable "Machine Height" Movement and Monitoring
on a Krones Labeler: Case History

Krones Labeler:
Monitors are based on Allen-Bradley PLC controllers to accurately monitor and control adjustable machine height(s). The sensor specifications include the following: input voltage: 24VDC; current: 400ma @ 24VDC; output: analog 0-10VDC; measurement range: ą4" typ. (specify); measurement repeatability: ą.001"; measurement accuracy: ą.005"; temperature range: 32° to 120°F; protection rating: IP 67. The hardware includes a NEMA 4X stainless steel enclosure for "washdown" protection and corrosion resistance, laser sensor and stainless steel sensing target. This technology helps to ensure agianst underfilling/lites for any bottling, filling or canning operation.

Downtime Tracking System
to Help Keep Track of Your Overall Equipmenet Effectiveness...

Downtime tracking and production monitoring systems provide an affordable, easy to use data collection system for your production equipment. Systems monitor and collect data for idle time, production time, and downtime. The software automatically records data based on shift, job, material type, part number, and operators. Inlcuded in the software are prgrammable downtime reasons, password protected editing, ethernet connectivity, and two-way messaging.

Downtime:

Data: can be displayed graphically using charting functions such as pie and pareto charts; reports can be generated by machine, job number, dowtime reason, operator, and shift

Portal features: it's a RISC processor based system running Microsoft Windows CE; ethernet connectivity is provided for data logging to any location on the local area network (LAN), or Internet

Portal configuration: supports established network connection using standard Ethernet/IP addressing; this gives the Portal the ability to work as a message center notifying operators of production requirements and broadcasting bulletins

Event tracking reports: include reason(s), job number, operator, shift, or theuser can add custom reporting via Seagate Crystal Reports

Supervisory control: can enter up to 25 different downtime reasons for each machine; establish editing control with a passowrd; programmable elapsed time to prevent nuisance dowtimes, and shift

Status Boards and Software
For Real Time Data Collection and Feedback Helps to Ensure a Smooth Running Line:

The ability to track your line data and procedure(s) in "real time" prior to and during various packaging operations is imperative for a smooth running line. A poor running line is a "DROP-DEAD ISSUE" for managers! There should be an adequate level of assurance that any issue that will occur during the routine packaging operation can be readily identified. An excellent way to track your packaging process is to use status boards and customized software that provide you with "real time" tracking data for your packaging operations.

Features:

Displaying and tracking real time data: can be accomplished with a "status board" and a customized software program; "status boards" provide a visual presentation of the "real time" data collection information you need for running your packaging lines. This information allows you to display, track and schedule your actual jobs and their progress.

Overall system: includes a large HDTV television display connected via a standard VGA cable to a PC computer. Customized software is developed (for your specific application) to allow for the display, monitoring, and tracking of the lines status, progress, etc., back onto the TV screen in "real time". The software will allow for easy entry of the packaging line data at the computer, based upon the existing line data sheets generated by the individual(s).

Automation Software with Signature Analysis

Features:

Prgram details: load display screen; signature analysis screen; comprehensive signature overlaying; signature storing/recalling; target signature overlay; peak history graph (stores up to 40,000 peaks/ch); comprehensive signature overlaying; signature storing/recalling peak history data export (Microsoft Excel format); SPC charts: individual and range, average and moving range (optional), median and moving range (optional);average and standard deviation (optional), printing (optional), and chart export in bitmap and meta file formats (optional)

Kits include: signature analysis software; USB analog adapter box 15' shielded ramcoder jack cable a maximum of 50'; USB 2.0 cable

System requirements: system can be a IBM PC compatible note book; a processor of 200MHz pentium or faster; a memory consisting of 32mb of memory or higher; an operating system of Microsoft Windows XP/7/8/10; and 1 available USB 2.0 port

Hand-Held Data Acquisition with Signature
Utilizing Bluetooth Wireless Connectivity

Features:

Connect: to Android OS, tablet and smart phone via Bluetooth

Android device: capture, store amd retrieve over 1,000 load signatures that can be viewed in real time, or, from memory; capture the last 200 tonnage overlaods, each overload is viewed with a date and time stamp; retrieve master load signatures for comparison to current production signatures

I/O Weigh Scale Modules
For Package Weighing Application Case Histories:

Very flexible with a low cost analog input for weigh-scale applications. They possess the following features: automatic transfer of load information to a PLC data table; built-in tare function; internal gauge excitation and signal conditioning; no external amplification is required and it has a calibration setting.

Rotary Filling Machine:
Includes a 2-channel module with 2 load cell inputs used in conjunction with an Allen-Bradley ControlLogix PLC control, and individual fill station load cells on a multi-station rotary liquid filling machine. The module prcecisely weighs and controls the flow of liquid product into the individual containers for each station. This is a special version strain gage weigh module used for general purpose weighing. Each station of the filler has its own load cell under the platform that supports the container. The stations with the load cells rotate continuously as the fill process happens, with new empty containers entering the start area of the filler, and full containers exiting the finish area. Due to the rotary motion, the PLC rack is typically mounted at the center of the filler, with all of the load cells wired to the strain gage weigh modules in the PLC rack. The strain gage weigh modules can be used on fillers with only one control valve per fill head, or, with fillers having 2 fill valves per head (coarse fill and fine fill). As the empty container starts the fill process at its station, a fill head with a fill nozzle, and 2 fill control valves (coarse Fill and fine fill) is in position over the rotating container. Comparing the target full-weight to the actual measured product weight in the container. The strain gage weigh module controls the flow rate, and flow duration for each valve at different stages of the process. Those control functions are done by discreet solid state outputs (coarse fill output and fine fill output) for each channel. The "COARSE FILL VALVE" has a high flow rate with a rough control fill function. The "FINE FILL VALVE" has a low flow rate with a precise control fill function. For any given container, the fill process starts initially with fine fill only, changes to fine and coarse fill, and changes back to fine fill only to fine tune the finish weight. A detailed bottle fill weigh, and fill timing sequence is as follows: Bottle on - Bottle detect threshold met - Weight stable - Tare evaluation - Tare set good/bad - PLC tare set acknowledged - Tare - Filling start - Fine fill only - Fine to coarse weight reached - Start coarse fill - Coarse fill (fine and coarse valves open) - Coarse to fine weight reached - Fine fill only - Continue fine fill - End weight stable - Bottle exit

Package Weighing System:
Includes SLC-500 strain gage "weigh" modules and "single point" type strain gage load cells. They were used to weigh/control each assembly operation where ingredients are added for two conveyor-fed pie lines. The quantities listed relate to those items needed for two identical "dual lane" lines (side by side), with 6 stations per lane to receive load cells (4 lanes with 6 stations/lane for a total of 24 total weigh stations). The modules were 2-channel Allen-Bradley SLC-500 high resolution strain gage input "weigh" modules. They were installed in an Allen-Bradley SLC-500 PLC to perform the weighing and control function. The load cells were PC 6-6kg "single point" weigh load cells. They were hermietically sealed with an IP-68 rating, for superior washdown protection. A load cell was installed at each of 6 "weigh stations" for each of the 4 assembly lanes. Modifications were made to the lines in order to create the individual weigh stations, and to incorporate the load cells. Two load cells will be connected to each of the 2-channel strain gage moduels (12 total modules). A custom load cell wiring interconnect system with J-boxes was included, to allow for the cable runs from the load cells back to their electronics.

Safety Light Curtains

Help protect personnel with fail-safe control reliability at the machine or on the line. An ideal technology for packaging operations or dangerous environments. These lights are a two component design that eliminates a seperate box for control. State-of-the-art circuitry allows the transmitter and receiver to be wired directly into the safety relay inside you control cabinet or PLC. An internal diagnostic circuit continuously monitors the operation of the lights for maintaining their UL and CE safety cerfitication. These lights also carry a category 4 safety rating - the highest level attainable by the international safety council. Standard protection heights range from 15 to 50" with beam spacing of 9 or 15mm. These lights can be programmed for either fixed or floating blanking with an SC-11 hand-held control module.

Specifications for Installations:

Safety light features: 9 or 15mm beam; LED indications of light intensity to aid in alignmnet; UL and CE approved; pre-wired to accept multiple light applications; detection range of upto to 30'; auxiliary output for PLC connection; protection height from 12 to 50"; complies with OSHA, ANSI, IEC1496-1, EN6496-1 safety requirements; self-checking control reliability; protection height 12" to 50"; 9mm beam spacing with 14mm minimum object sensitivity with a protection height of 12" to 50"; 15mm beam spacing with 25mm minimum object sensitivity, protection height 12" to 50" with additional lengths available, eac set of lights includes 1 transmitter, 1 reciever and 2 23' interconnect cables, with double ended cables for series connection are available

Safety light specifications:

Supply voltage: 24 VDC +/-10%

Light source: infrared LED (870nm wave length)

Response time: 10 to 15msec

Beam spcaing: 9 or 15mm

Scan distance: up to 33'

Certified compliance: OSHA, ANSI, 1EC61496-1, ENC61496-1, and UL508

Fixed and floating blanking is available: needed is an SC11 module; key features of this module include numerical indication of blanked beams, memory storage, download capability, and password protection

Weigh Module Applications

Designed for static weighing applications. The weigh modules provide 2 independent channels of weigh scale measurement. Each weigh module can accept two 350 ohm strain gages, or, up to four 700 ohm strain gages. They're compatable with most industry standard load cells. The sensors may be wired directly into the module, simpllfying the installation. With a self-contained power source, no external amplification is required. Calibration settings are programmable. Weigh modules are available for 1734(Point I/O, 1746(SLC500), 1756(ControlLogix), and 1769(Micro/Compac) series of prgrammable controllers.

Applications: for the Allen-Bradley (SLC-500 (1746), ControlLogix (1756), MicroLogix/CompactLogix (1769), Point I/O (1734), and Micro850 (2085) PLC

Module features: automation transfer of load cell weigh module information to PLC data table; built-in tare function; integral gage excitation and signal conditioning; no external amplification is required; programmable calibration setting

Module specifications: 16 to 24 bit A to D, internal conversion rate 100 microseconds; input range .1mV/V to 4mV/V; overal module accuracy is 0.01% of full scale; self-contained power source

Weighing Load Cells and Applications

These cells are designed specifically for static weighing applications. Each load cell offers a wide range of capacities and is specifically tested to meet international metrology standards.

Applications: from test measurement equipment to silos

Beam load cell: floor scales, tank and silo weighing, filling operations

Compression load cells: tanks and silos, weighbridges, and any heavy weighing, or load measuring applications

Tension load cell: tanks and silos, hoists, test and measurement equipment

Single point load cells: bench and floor scales, checkweighing, bagging, hopper and tank weighing

Planar beam load cell: small and large scale weighing

TechSourceŽ will provide you with affordable and sensible solutions to correct your packaging problems. We'll supply you with the expertise you need to be successful in eliminating those unusual issues in your packaging operation!

PLEASE NOTE: Pharmaceutical Production TechSourceŽ makes every reasonable attempt to ensure the accuracy of the information we provide for each piece of equipment or part. The purchaser should verify any information or specifications with either their knowledge of the equipment, or, have the equipment inspected by a qualified person. Measurements and shipping weights are approximated or estimated. We are not responsible for any errors or omissions contained in any advertising materials, including this website, as well as any quotation or other documents which may contain a description of the equipment. All quotes are valid for 30 days, and all goods are subject to prior sale. Prices do not include creighting, freight, insurance, taxes, fees, etc.

PLEASE NOTE: Quotes for equipment DO NOT include crating, freight, or insurance costs (CFI), taxes, tariffs, etc. are additional.

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