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Customer Overview
A leading machine builder developed a next-generation Multi-Station Thermoforming Machine to produce food containers, trays, lids, clamshells, and other thermoformed packaging products. The machine integrates multiple manufacturing processes—including sheet feeding, heating, forming, cutting, punching, and stacking—into a continuous automated production cycle to achieve higher productivity, precision, and operational efficiency.
Customer Challenges
The customer required an advanced automation platform capable of delivering:
- High-speed synchronized multi-axis motion control for seamless machine operation.
- Precise forming and cutting to ensure consistent product quality.
- Production speeds of up to 45 strokes per minute, subject to application and mechanical constraints.
- Flexible recipe management for quick product changeovers.
- Station-wise enable/disable functionality for different production configurations.
- User-friendly HMI with advanced diagnostics and alarm management.
- Smooth motion profiles to reduce mechanical wear and improve machine life.
Inovance Solution
After evaluating the application requirements, Inovance delivered a complete motion-centric automation solution built around its integrated control platform.
The solution included:
- AM5 Motion Controller for synchronized multi-axis control
- SV Servo Drives with MS1 Servo Motors
- IS650N Servo Drives with ISMG Servo Motors
- IT7 HMI for recipe management, diagnostics, and secure user access
- GL20 EtherCAT Modular Remote I/O
- MD520 AC Drives for auxiliary applications
The system provides synchronized control of sheet indexing, forming, plug assist, cutting, punching, and stacking operations while ensuring smooth, high-speed machine performance.
Key Benefits
- Achieved stable production speeds of up to 45 strokes per minute.
- High positioning accuracy and synchronized multi-axis motion.
- Improved product consistency and dimensional repeatability.
- Faster mold changeovers through recipe-based operation.
- Reduced machine downtime with intelligent diagnostics and alarm management.
- Flexible machine configuration using EtherCAT modular I/O.
- Reliable 24×7 operation with scalable architecture for future expansion.
Results
By implementing Inovance's integrated automation platform, the machine builder successfully modernized its thermoforming machine with a high-speed, reliable, and scalable control system. The solution delivers consistent product quality, enhanced operational efficiency, reduced maintenance requirements, and supports continuous 24×7 production, making it an ideal solution for high-volume thermoforming applications.