Automation Case Study: Revolutionizing Paper Cup Manufacturing with Customized E-Cam Solution

Customer Profile:

A leading family-owned enterprise, established in 1979 and headquartered in Kochi, Kerala, India, is a pioneer in the packaging and printing industry. Over the years, the company has diversified into multiple industries and is now India's largest manufacturer of sustainable paper products, including paper cups, paper lids, and straws. With international certifications such as Indian CPCB, European EN 13432, and Australian AS 5810, they are also a key exporter of sustainable technology and dispersion coating chemicals for packaging applications.

The Challenge:

The company faced challenges with its paper cup-forming machine. The rotary index axes operated in absolute mode without a home sensor, requiring an upgrade to remove all mechanical cams and implement an electronic cam (E-Cam) function for better precision and efficiency.

The Solution:

To address these challenges, Inovance Technology provided an advanced automation solution comprising:

  • SV660N Series EtherCAT Servo Drive
    • 1/3 ph 220 V, 3 ph 380 V
    • 0.1 kW to 7.5 kW
  • MS1H Series Servo Motor
    • Support for 14-bit, 18-bit, 23-bit, and 26-bit optical/magnetic encoder
    • Power : 0.05 kW to 7.5 kW
    • Frame size : 40, 60, 80, 100, 130, 180
  • AC703 Intelligent Motion Controller (IPC)
    • Webvisu functionality
    • Embedded remote commissioning and industrial IoT functions
  • IT7000 Series HMI
    • 4.3”, 7”, 10” & 15” display sizes
    • IP65 rating (front side), IP20 panel
    • VNC remote access and support for OPC UA, Modbus RTU/TCP and MQTT protocols

This solution enabled the customer to reduce mechanical components and transition to a more synchronized and efficient electronic cam operation. Direct supply of components was ensured, and our dedicated salesperson interacted closely with the customer to facilitate a seamless transition.

Interested? Contact our sales department

Benefits:

The implementation of Inovance's automation solution significantly improved production efficiency. Using Inovance’s dedicated library for E-Cam and GearIn functions for synchronization, the company achieved a production rate of 70 to 100 cups per minute, enhancing operational precision and reducing mechanical wear and tear.

Key Benefits:

  • Elimination of mechanical cams, reducing maintenance requirements

  • Higher precision and synchronization with the E-Cam function

  • Increased production speed and efficiency

  • Enhanced reliability with absolute mode operation

  • Seamless customer support and direct product supply

Conclusion:

By adopting Inovance Technology’s automation solutions, the customer successfully enhanced their production efficiency and streamlined operations. The transition from mechanical cams to E-Cam functionality has positioned them for improved scalability and long-term growth in sustainable packaging solutions.

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