Automation Case Study: Reducing Spillage with Anti-Sloshing Technology

Customer Profile:

A pioneer in packaging since 1990, this company is renowned for its innovative approach and commitment to quality. Headquartered in West Yorkshire, UK with manufacturing facilities in India, it offers a wide range of packaging solutions across industries such as food and beverage, pharmaceuticals, and consumer goods. Its strengths lie in its innovation, customer-centric approach, commitment to quality, and corporate social responsibility.

The company is renowned for its:

  • Flexible Packaging (e.g., pouches, bags, films)
  • Rigid Packaging (e.g., containers, bottles, jars)
  • Custom Packaging (tailored to specific client needs)
  • Sustainable Packaging (recyclable and biodegradable options)

Challenge:

In the highly competitive filling and packaging machine industry, Original Equipment Manufacturers (OEMs) like them face several challenges:

  • Precision and Efficiency: Accurate positioning of containers to prevent spillage and waste during the filling process.
  • Innovation and Customization: Adapting machines to client-specific needs.
  • Cost Effectiveness: Offering high-performance machines while maintaining affordability.
  • Compliance: Meeting regulatory and safety standards.
  • Global Competitiveness: Staying ahead with technological advancements and sustainable practices.

The paint container filling machine presented a specific challenge due to the need for precise container positioning and seamless conveyance through different stages of the filling process. The customer required a solution that could improve efficiency while ensuring the accuracy of filling to prevent paint spillage.

Solution:

Inovance Technology collaborated with the customer to address these challenges. Inovance supplied a comprehensive motion control solution for the paint container filling machine:

  • Controller: AM401-CPU1608TP-INT
  • Servo Drive: SV660NT8R4I-INT
  • Servo Motor: MS1H2-20C30CD-A331Z-INT

This solution offered a high-performance, cost-effective system with features that significantly improved the operational efficiency of the filling machine:

  1. Precise Positioning: The servo motor-driven conveyor accurately positioned containers under the filling nozzles, minimizing the risk of spillage and ensuring consistency in the filling process.
  2. Ethernet IP Communication: Integration with SCADA systems via Ethernet IP protocol enabled real-time monitoring and control, enhancing automation and data visibility.
  3. Smooth and Efficient Operation: The EtherCAT-based motion control system facilitated smooth and high-speed movement, reducing the risk of bottlenecks and jams in the production line.
  4. Anti-Sloshing Algorithm: Inovance’s servo motion controller featured an anti-sloshing algorithm, preventing liquid (paint) from spilling due to sudden movements by optimizing the motion profile.
  5. Vibration Suppression: The AM401 controller included a specialized vibration suppression function, which reduced mechanical vibrations during acceleration and deceleration. This technology minimized disruptions in high-speed operations, improving filling accuracy.
  6. Safety: The servo system included the STO (Safe Torque Off) safety feature, ensuring compliance with industrial safety standards.

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Benefits:

By implementing Inovance’s solution, customers experienced several advantages. The precise container positioning and smooth movement enhanced overall production line efficiency, minimizing downtime from jams or bottlenecks. The anti-sloshing feature of the servo motion profile cut down on spillage, leading to cost savings and a cleaner facility. Inovance’s system delivered comparable performance to existing solutions but at a lower cost, with high responsiveness and built-in safety features. Additionally, the integration of EtherCAT and SCADA systems provided improved control and flexibility, optimizing operations and offering real-time insights into machine performance.

Key Benefits:

  • Increased Efficiency
  • Enhanced Control and Flexibility
  • Minimized Spillage
  • Cost-Effective Solution

Conclusion

Inovance Technology’s partnership with the customer has resulted in a highly efficient and precise paint container-filling solution. Inovance’s advanced servo motor and motion control system not only improved the performance of the filling machine but also ensured cost-effectiveness, safety, and reliability. This case demonstrates how innovative automation solutions can overcome industry challenges and drive operational excellence.

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