Linear transport setup boosts Tetra Pak cap application speeds to match upstream line

The integration of Beckhoff’s linear transport technology into the process has allowed Tetra Pak engineers to avoid the limitations of the slower all-mechanical alternatives.

Traditionally, says the beverage carton systems manufacturer, closure applicators based on standard handling systems could not reach speeds above around 9,000 cartons per hour (cph). By utilising a combination of Beckhoff’s XTS linear transport system and PC-based control, the new 40 Speed Hyper applicator can handle up to 25,000cph.

The end result is that drinks producers can meet their output requirements without having multiple cap applicators occupying valuable factory space.

The XTS system consists of two 4.5m tracks, each with 55 ‘movers’, which each act as an independently-controlled servo axis, providing huge flexibility – and also speed, explains Beckhoff’s UK sales manager Mark Richards.

“In order to sustain these high speeds, synchronised groups of movers in batches of six apply hot-melt adhesive and press caps on to cartons in perfect alignment,” he says. “The in-built quality control uses a vision system to detect any deviations and automatically adjusts glue patterns and force profiles accordingly without the need for manual stops or wasteful downtime.”

All of this is orchestrated by Beckhoff’s PC-based control running on two ultra-compact C6032 industrial PCs. The control architecture relies on TwinCAT software for motion, vision and PLC tasks, says the technology supplier, with millimetre precision and microsecond response times.

“High packaging speed means little without consistent uptime,” says Richards. “Tetra Pak’s new system can adapt instantly to changing product formats, cap types and packaging lines. The process doesn’t just move faster, it runs more reliably too. By replacing complex mechanical parts with software-defined motion, mean time between failures (MTBF) has doubled.”

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www.beckhoff.co.uk