In recent years, the world of end-of-line packaging experienced major developments. The owner of Tallgroup and Technical director of Tallpack Bulgaria, Mr.Hubert Verheul shares an insight into the challenges and technological advances within this sector.
The focus is not only on improving the stability of pallet loads, but also on sustainability, energy consumption and flexibility of packaging lines.
‘One of the biggest challenges for end-of-line packaging machines lies in the area of load stability, recycling and reducing the carbon footprint’, states Mr. Verheul. ‘Customers ask today mainly how they can pack their products with maximum stability using a minimum of packaging material, while at the same time using sustainable materials. The quality of recycled packaging material in particular plays an important role in this. If it is not sufficient, the pallet load can become unstable.’
The focus on energy consumption has also increased. Innovations such as energy recovery within packaging machines or lines are increasingly being used. Hubert Verheul gives the example of a stretch hood machine, where the energy released during vertical downward movements is stored and reused. These techniques, comparable to energy recovery in electric cars, ensure that 24V systems, for example, can continue to function without consuming additional energy.
Efficiency through innovation
End-of-line packaging machines should not only be more sustainable, but also be more energy efficient. Technical director of Tallpack Bulgaria notes that traditional systems such as heat-based shrink hoods are increasingly being replaced by stretch hoods mainly due to energy consumption. Stretch hoods are 20% lighter than shrink hoods and use a memory function, which means that the film tightens around the pallet after stretching. In many cases, depending on their energy consumption, companies can recoup packaging lines within a few years through energy cost savings. However, the shrink hood remains necessary in specific sectors, such as the glass industry, where stretch hoods cannot be used because round products on a pallet are not dimensionally stable and the film can bounce back on the corners when someone pulls the glass jars out and then they can fall.
Flexibility and ease of use
The flexibility of final packaging lines is more important than ever, shares Mr. Verheul. Packaging shapes and sizes are changing increasingly quickly, often driven by environmental considerations and consumer demands. ‘End of line packaging machines must be flexible enough to respond quickly to changes in primary and secondary packaging,’ says Hubert Verheul.
In addition, the labor shortage plays a role. Operators increasingly come from abroad, which requires user-friendly final packaging machines or lines that can be operated in multiple languages. Modern packaging lines are equipped with large, intuitive touchscreens, on which operators can easily switch between languages such as Bulgarian, English, Dutch, Polish or other languages. In addition, alarm systems and operating menus are equipped with pictograms and visual instructions, which makes operating machines easier, regardless of the language or background of the operator.
Robotization
Robotization and automation have now penetrated deeply into the packaging industry. Small robots or cobots are becoming increasingly affordable and play a major role in performing repetitive and/or complex packaging operations. What used to have to be done by complicated mechanical systems can now be easily performed by a robot.
Monitoring systems, equipped with cameras, also offer intelligence with which robots can, for example, stack products with constantly deviating sizes on pallets. ‘Where this used to depend on the intuition of an employee, machine learning takes over this task’, declares Hubert Verheul. ‘Cameras are also used to monitor critical processes within end-of line packaging and prevent errors.’
Paper and recycled materials
Hubert Verheul sees the future of end-of-line packaging adapting to more paper packaging, especially for lighter products. Plastic packaging will certainly continue to play a role now and in the future, especially in heavy industries such as steel and construction materials.
Using recycled plastic is in line with EU obligations, whereby companies must use at least 50% recycled material by 2030. The first tests with 100% recycled material are now underway. Hubert Verheul warns however that 100% recycling is difficult to achieve, because there is always a loss of material.
Artificial intelligence
Although artificial intelligence (AI) does not yet play a major role in the packaging sector, for example in troubleshooting, Hubert Verheul does see a future for AI in maintenance processes. For example, AI can help to draw up maintenance schedules and optimize machine components based on usage data.
In the area of malfunctions, Technical director of Tallpack Bulgaria expects virtual reality (VR) to play an important role. Technicians can use VR to remotely view operators and give instructions to resolve malfunctions. The technology which uses a helmet with an integrated camera and microphone is already being carefully tested and tried at Tallpack.
Industry in motion
‘The end-of-line packaging industry is not standing still,’ concludes Hubert Verheul. ‘Innovations in energy efficiency, sustainability, flexibility and robotization are at the heart of latest developments. Although traditional packaging systems still have a place, the future lies in intelligent and flexible solutions that help companies to pack more efficiently, sustainably and cost-effectively. Innovations such as AI and VR will only further transform this sector in the coming years.’
English (Английски)
