The traditional Programmable Logic Controller (PLC) has dominated the global control landscape across food and beverage plants for the last twenty years. Having just one manufacturers range of equipment has brought a range of benefits to the End User, lowering downtime and increasing efficiency. However, over the last ten years we have noticed significant increases in the speed and flexibility demands of packaging lines that are challenging the use of traditional PLCs.
Driving change in the packaging industry: Today, we’ve noticed that the biggest focal point for investment in the food and beverage sector is in the packaging side of the business. You may ask why? Well, quite simply it’s because this is the most likely area to generate added profit. In the UK, the basic products and processes for making our food does not change frequently. The only reason this would change significantly is if there were a seismic change in technology. The biggest drivers in the packaging industry include: shelf ready packaging, maximising product shelf density, utilising safer and more sustainable materials and the use of lighter packaging for refills. In food and beverage production, the largest proportion of factory labour resides in the packaging areas. There is an ever-compelling case for the use of automation and robotics as access to low cost labour gets more difficult, the minimum wage increases and there is more focus on health and safety at the same time the cost of the technology is reducing.
The future of automation and robotics in the packaging industry: Whilst PLC based automated packaging equipment was commonplace twenty years ago, packaging equipment was often synchronised with mechanical cams and product picking done almost entirely by humans. In the 2000’s we saw many picking and packing lines with a combination of PLC’s and robot controllers each with their own programming environments but joined by a network. In the last 5-10 years we have witnessed OEMs building or buying standalone mechanical robot arms and integrating PLC based motion control of the same type used to control the rest of the packaging line. Whilst the control systems are consistent they require multiple controller and often many control cabinets for the complex lines.
A new generation of control for high speed picking and packing: Picking and packaging lines have come a long way. Manufacturers no longer have to convince end users to use them – and this is key. We’re witnessing increasing demands for faster lines that require multiple robots and sequenced motion axes. These need to fit into existing factories that have limited space and be fully IIOT enabled. The traditional PLC based architecture becomes more and more limited as the number of robots increases. For this reason, traditional PLC based control architecture will be phased out for this type of line in favour of a new generation of ultra-high-performance motion and robotic controllers, which also have PLC sequence capability.
Ultimately, not only do these controllers outstrip the PLC for this control, but they also offer full IIoT connectivity and benefit a whole series of digital tools for remote tracking, monitoring, optimisation and remote services including the latest augmented reality support tools. Schneider Electric’s compact PacDrive3 is leading the way in this technology and can be used to control a series of Schneider Electric picking robots and a wrapping machine all from the one controller. By using motors with integrated drive electronics, panel space is kept to an absolute minimum.
Author: By Martin Walder, VP Industry, Schneider Electric
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