26/01/2022 Stratus Technologies Systems Ltd
By Garry Lewis Market Development Manager at Omron
In every area of our society, we are looking to reduce our use of non-recyclable materials and replace them with more sustainable alternatives. One area that this can be seen is in the use of plastics in packaging of our food and commodities.
Here we look at a few examples of how manufacturers of food packaging equipment are using technology to overcome the challenges when looking to use more sustainable materials.
In the UK it is estimated that five million tonnes of plastic are used every year, nearly half of which is packaging. Latest statistics from WRAP[1], state that in 2020 an estimated 1.2Mt (megatonnes) of the UK’s plastic packaging was recycled, a fourfold increase from levels achieved in the early 2000s.
The UK is now looking to increase domestic capacity to recycle and reuse plastic waste, as well as consulting on policies to improve the quality of recovered plastic and create demand for recycled plastics.
There are several ways to achieve this when it comes to food packaging, which when carefully implemented can enable a more sustainable future.
Thinner, recycled films are more sustainable, but can also tangle more quickly. Even slight changes in film thickness leads to uneven winding and unwinding and increase the tension on the film.
Uneven tension, in turn, causes defects during pouch forming or sealing, such as curling, ripping, folding, or a sideways shifting or misalignment. Correct handling with maximum throughput and minimum film consumption is key to overall OEE (Original Equipment Effectiveness).
If creases are forming in the seal, operators need to check for machine errors that are contributing to the film not being fed correctly. Examples include misaligned rollers, different feeding devices, or stuck rollers that do not rotate freely.
To overcome this, Film Tension Control Systems are being used to provide synchronised control of tension, feed, and cut. This can be complemented by (colour) mark detection for film compensation through motion control to ensure optimal unwinding of the roll.
Re-closable packaging or pouches with nozzles are also increasingly replacing rigid plastic containers. Flexible packaging with new elements such as resealable closures place different demands on packaging integrity and quality testing.
Thinner films, bio-based materials, or those with a higher recycled content have a different thermal, elongation, and puncture resistance profile. These differences can lead to irregularities in the shape and edges during forming and cutting.
More sustainable materials such as non-laminated or monomaterials also change shape and can reduce the fidelity or performance of label printing. Reading, checking, or verifying label information on packaging is difficult when the shape is inconsistent, or the print quality changes.
Scalable systems to reduce waste
To address this, High-Speed Inspection Systems are now being used. This simple and scalable system can be suitable for multiple lines and transparent integration when integrated with robotic systems.
To reliably detect potential defects an additional level of a multi-camera platform with a single controller for multiple-image capture at high speed can be used. Advanced algorithms can also help to detect difficult-to-read characters, in variable light conditions and high speeds.
Eliminating tapes and minimising adhesives increases the recyclability of cartons. Removing the need for a silicone strip makes it 100% recyclable and biodegradable. To produce and seal cartons, companies are increasingly relying on a strategic and reduced application of adhesives. This requires a high level of precision and continuous quality control.
To achieve this, manufacturers have turned to automated visual inspection system for detection of glue patterns. The high resolution and brightness settings of these systems allow low-contrast defects to be detected, even in the toughest light conditions or with difficult to detect materials.
Lastly, instead of tackling the battle to be more sustainability alone, manufactures have looked to bring strong technology partners on board.
OMRON is one example of this and has offered complete solutions for sustainable packaging line automation that has helped companies become more efficient and greener, utilising existing machines for new recyclable materials while maintaining product quality.
Ultimately, the food industry is undergoing a revolution in terms of finding sustainable solutions to reduce its impact on the environment and meet sustainable consumer demands. It is our duty to embrace innovative food packaging to transform the sector, together.
[1] Plastics Market Situation 2021: https://wrap.org.uk/resources/report/plastics-market-situation-report-2021
For more information, please contact: Stuart Coulton OMRON Industrial Automation Opal Drive Fox Milne Milton Keynes Bucks MK15 0DG Tel: 01908 258124 Email: stuart.coulton@omron.com Web: www.industrial.omron.co.uk/en/home
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