Mitsubishi Electric’s automation solutions increase reliability and double speed of legacy paper roll packing machine.
Mitsubishi Electric has supported Optimation, a machine builder specialist in the packaging and converting industries, in an automated till roll packing system upgrade project. The improved setup combines a MELSEC iQ-F PLC, MR-J4 servos as well as a GOT2000 series HMI, doubling the speed of operations while maximising availability and durability.
[Source: Mitsubishi Electric Europe B.V.]
Bringing packing machines into the future
When a manufacturer of till rolls wanted to expand its production and improve the availability of its 20-year-old packing units, it asked the Derbyshire-based machine builder to refurbish them. Steve Richardson, Managing Director at Optimation, explains: “Our customer was keen on improving the availability of its existing machines, as unexpected breakdowns were costing tens of thousands of pounds per day. In addition, the manufacturer wanted to futureproof the units, making sure these would offer reliable, high-speed service for another 20 years. This would enable the company to enhance its competitiveness and leverage cutting-edge technology to ensure smooth operations.”
[Source: Mitsubishi Electric Europe B.V.]
While highly innovative for their time, the machines were relatively slow by today’s standards. In addition, it was becoming increasingly challenging for the till roll producer to find specialists able to repair the equipment in the event of failure, due to the unit’s obsolescence and complex coding behind the design. To deliver a refurbished system that would address these issues, Optimation chose to rely on Mitsubishi Electric’s automation products and services.
Sebastian Viteri, Account Manager at Mitsubishi Electric, comments: “The project required more than a simple upgrade of the existing controllers and servos with newer solutions. Since the machines heavily relied on the program code for accurate and responsive movements, rewriting it and utilising advanced motion control systems was fundamental to ensuring optimum operations.”
Futureproofing automation components
The Mitsubishi Electric iQ-F series PLC was identified as the ideal controller for this project; offering high performance, advanced system control and user centric programming. By combining it with MELSERVO MR-J4 servos, which are well suited to packaging and handling applications, the resulting setup would offer the long-lasting high performance that the till roll producer was looking for. The upgraded system was also equipped with a GOT2000 series HMI to allow operators to monitor as well as interact with the pick and place processes.
[Source: Mitsubishi Electric Europe B.V.]
Steve Richardson adds: “This was a particularly demanding project from many points of view, from selecting the ideal components to rewriting the existing code. Thanks to the high-quality automation solutions and continuous technical support provided by Mitsubishi Electric we could deliver highly reliable machines to our customer that have expanded their production. We are extremely satisfied with the results of this collaboration and based on this, we decided to work together with Mitsubishi Electric on four additional refurbishments of similar machines for the converting industry.”
Further Information:
Website: gb3a.mitsubishielectric.com