1 The most innovative machines with Rockwell Automation solutions solutions Innovative Maschinen mit Lösungen von Rockwell Automation
3 Table of Contents/Inhaltsverzeichnis English Company Country Page Big Drum Engineering Germany 4 Cama Group Italy 6 CFT Italy 8 Elmar Europe Germany 10 GEA Messo PT Netherlands 12 Haas-Mondomix Netherlands 14 Ice Group Poland 16 Langen Group Netherlands 18 PFM Italy 20 Tramper Technology Netherlands 22 Deutsch Firma Land Seite Big Drum Engineering Deutschland 24 Cama Group Italien 26 CFT Italien 28 Elmar Europe Deutschland 30 GEA Messo PT Niederlande 32 Haas-Mondomix Niederlande 34 Ice Group Polen 36 Langen Group Niederlande 38 PFM Italien 40 Tramper Technology Niederlande 42
4 Solutions in Action BIG DRUM Engineering has recently introduced smaller systems, such as the Smart Filler XW The roots of BIG DRUM date back to 1928 when Mr. Parker first established the Drumstick Company, a company that filled wafers with ice-cream, in Forth Worth, Texas. Today, BIG DRUM ranges among the leading players in the global ice-cream industry. Allen-Bradley CompactLogix programmable automation controller Allen-Bradley Kinetix 5500 servo drives Our real strength is due to consistently focusing on one field. We are THE specialist when creating filling solutions for ice-cream or other food, Andreas Itter, sales & marketing manager, describes. BIG DRUM Engineering GmbH based in Edertal-Giflitz has developed, manufactured and installed filling lines on the global market for a long time. 70% of sales are achieved from export of machines built by the company based in Northern Hesse. Our systems fill creamy and liquid products into various containers and achieve an output of up to 50,000 pieces per hour depending on the container size, Andreas Itter declares. Generally, speed is an important issue for BIG DRUM filling solutions, along with proper hygiene conditions and the highest possible user friendliness all the things that machines manufactured by BIG DRUM put into practice by default thanks to Allen- Bradley components amongst others. Andreas Itter gives the following reasons for this choice: Rockwell Automation offers trainings free of charge at the customer s site,
5 worldwide support via service centres staffed around the clock and any quantity of highly qualitative products that are very easy to operate. In all Allen-Bradley controlling systems for example, certain routines are pre-set, so that our programmers only have to modify specific values, curves or degrees. In general, BIG DRUM Engineering is best known for large-scale, highly complex and extremely speedy filling lines. Recently, the mechanical engineering company has offered even smaller systems, such as the Smart Filler XW, an extremely compact series concept, whose small dimensions and transport rollers provide easy shifting from A to B, if required - into the middle of production or anywhere outside in storage facilities. Another example of a small mechanical BIG DRUM solution is the Sandwich Line SL200. This system was created at the end of 2013 and is very popular on the US market, in Scandinavia and in Russia. This equipment line copes with up to 165 to 170 cycles per minute, depending on sandwich size or paper quality and can also be operated by an Allen- Bradley touch screen. The drives required for such filling speeds are provided by Rockwell Automation in this case, too. That s what we re all about. Rockwell Automation is our preferred technology partner, because everything is just perfect: The product, the support and the worldwide service, Andreas Itter concludes. The Smart Filler is designed to fill cones, cups and other standardised products and can be configured from six products wide down to a single lane. Depending on customer needs, an Allen-Bradley CompactLogix or a Compact GuardLogix programmable automation controller (PAC) keeps running the machine at a cycle rate of 65 to 70 cycles per minute. An Allen-Bradley Kinetix 5500 servo drive running over EtherNet/IP maintains the exact positioning of the products in the single stations of the Smart Filler, especially in the lidding station. Here accuracy is particularly important, Andreas Itter underlines. The Smart Filler provides absolute flexibility due to the user-friendly Allen-Bradley PanelView Plus 1000 graphic terminal. At the push of a button, it is possible to select the product to be filled, such as cones or cups filled with vanilla or chocolate ice-cream. The great thing about the operator panel is that pictures, manuals and short videos can be stored for the operator, who can then display them for operation or maintenance purposes, the marketing & sales manager of BIG DRUM Engineering reveals a further special feature of the controlling solution from Rockwell Automation that he particularly appreciates. For more information, contact: Andreas Itter, Sales & Marketing Manager BIG DRUM Engineering GmbH Phone: Fax: Allen-Bradley, CompactLogix, Compact GuardLogix, Kinetix, LISTEN. THINK. SOLVE., PanelView Plus and Rockwell Automation are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVA Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication OEM-AP422A-EN-P February 2015 Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.
6 Solutions in Action Cama Group is known globally for the cutting edge technology and reliability of its packaging systems. The packaging machines and the robotized lines, designed, manufactured and installed by the Italian company worldwide, can be used in food and non food industries and cover the whole primary and secondary packaging processes, from the line entrance to the end-of-line packaging operations, before palletising. itrak, a modular, scalable motion control system Cama is now introducing the CL 175, a new cartoning machine, which has been completely redesigned, both in layout and functionality. The main difference between the CL 175 and other traditional cartoning machines lies in the itrak system, a solution designed by Jacobs Automation, an American company recently acquired by Rockwell Automation. itrak is a modular, scalable motion control system that provides independent control of multiple magnetically propelled movers on a track; the simple configuration and patented pitch-less technology conceived by Jacobs Automation changes the industry approach to transport systems and solves different motion and speed needs. Allen-Bradley GuardLogix L71S As Riccardo Panepinto, Operations Director at Cama Group, explains: This cartoning machine is the most popular system among the ones proposed by Cama and it is now showcased in a totally new version, which includes the no-chains intelligent track system designed by Jacobs Automation. The system is totally integrated with the Rockwell Automation hardware and software technology, selected by Cama to build the automation and control core of the machine.
7 The CL 175 is the result of a restyling that Cama Group recently started to reduce its machines footprint, by integrating the electrical and pneumatic component control cabinets into the machine pedestals angles. Such a compact machine footprint helps to minimize cabling and makes it easier to place the utility devices right where they are needed and make them more accessible. Going into detail, the CL 175 comprises three main operating stations: in the first one, the carton box is picked from the storage station, opened and placed into the movers pockets. After that, it moves to the next station for the product insertion. Two boxes at a time are picked and placed in continuous motion, with movers adapting their speed to that of the rotary feeder. The boxes remain instead in a stand-by position to receive the items. As this step is completed, the carton boxes are moved towards the final closure station, which can work in continuous or intermittent mode. The movers are electronically aligned with the devices operating in the different stations; they move independently of each other and adapt to different speed requirements, Panepinto points out. To build the control core of the cartoning machine, Cama selected a Rockwell Automation GuardLogix L71S controller. The controller is connected to the movers over EtherNet/IP and through a gateway, which runs as a hardware and software interface and reads the movers as if they were machine s virtual axis. To manage the movers, the operator uses a programming environment which is common to all the Rockwell Automation midrange solutions adopted on the machine: Allen-Bradley Kinetix 5500 servo drives, single-cable motors, Allen-Bradley PowerFlex 525 inverter, safety Point I/O, I/O for Fieldbus connection to pneumatic components, Stratix 2700 switch connected to other operating units and Allen-Bradley PanelView Plus operator panels running Windows CE. The Jacobs Automation itrak and Rockwell Automation midrange control and motion solutions helped Cama to manufacture a machine which offers several benefits to the end user: optimised format changeover, reduced footprint, lower maintenance needs and energy savings. The automatic changeover doesn t require manual intervention and it is key to the machine performance improvement too. Featuring 10% reduced floor space and an advanced control software system, the CL 175 uses less steel in its construction, reduces the environmental impact and doesn t require any chemical products in maintenance operations, since the movers don t need to be lubricated, Panepinto says. It is also worth mentioning the reduction in electrical consumption, due both to the fact that every mover starts only when it is needed and to the adoption of Rockwell Automation energy efficient midrange solutions. Furthermore, on CL 175 there is no need to restart the system in case of an emergency stop: While in traditional packaging systems motors need some seconds to find their home position in case of restart after a stop, the absolute encoders set on each itrak mover retain position data during loss of power and allow the machine to restart immediately, Panepinto concludes. For more information, contact: Riccardo Panepinto Operations Director Cama Group Phone: Fax: Listen. Think. Solve., Allen-Bradley, GuardLogix, Kinetix, PowerFlex, Stratix and PanelView are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication OEM-AP270A-EN-P MARCH 2014 Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.
8 Solutions in Action CFT designs and manufacture turnkey lines and single machines for liquid food processing and packaging Allen-Bradley CompactLogix programmable automation controller (PAC) Allen-Bradley PowerFlex 525 variable-speed drives Catelli Food Technology (CFT) is a world market leader in food processing and packaging line construction. Based in Parma, Northern Italy, the CFT Group was born in 2006 from the merger of two 80-year-old, worldwide food plant engineering and manufacturing companies Rossi & Catelli and Manzini. CFT works with the biggest multinational food companies around the world to develop innovative solutions, which boast made-in-italy technological excellence. We design and manufacture turnkey lines and single machines for liquid food processing and packaging, Mario Gozzi, Sales Area Manager at CFT for US and South America, states. We are world leader in fruit and tomato processing, aseptic bulk filling, liquid food concentration, beverage, sauces and beer filling and seaming. Among our customers, we count brands such as The Morning Star Packing Company (US), Sugal Idal (Portugal), Transa (Spain), La Cesenate (Italy), Cofco Tunhe (China) and Kagome (Japan). CFT recently engineered a completely new line for high-quality fruit purée processing. The new line at Titan Frozen s Santa Maria site, with an incoming flow rate of 5 t/h, is designed to produce single-strength strawberry purees and concentrates either natural or depectinized which are cold filled into 55 gal bags in drums and then frozen. This
9 semi-processed food product is aimed at the beverage industry as well as at the yogurt, dessert and ice cream production markets. The Titan strawberry puree line comprises two unique and proprietary CFT technologies, the Zenith Chrono line for fruit puree extraction and the Mixflow evaporator for final fruit puree concentration. The Zenith Chrono line features a new patented concept as the fresh fruit is processed thanks to three basic elements anaerobic environment, cold extraction and fast enzymatic deactivation while the Mixflow evaporator has a traditional forced-recirculation body on the first effect followed by second and third effects with mixflow technology, Gozzi details. When engineering the Titan s line, CFT chose a midrange control and supervision solution from Rockwell Automation, which is based on the Allen-Bradley CompactLogix programmable automation controller (PAC) and Allen-Bradley PowerFlex 525 and 753 drives. The CompactLogix PAC, which runs the overall processing functionalities in the line, talks directly to drives and to the HMI platform, thanks to an EtherNet/IP communication network. CFT developed and tested the HMI applications for the Titan line using the FactoryTalk View SE HMI solution from Rockwell Automation. Rockwell Automation satisfied our crucial need to deploy a fully integrated midrange automation solution both for process control and supervision, Gozzi says. The Rockwell Automation midrange solution complemented the innovation and excellence of our proprietary Zenith Chrono extractor and Mixflow evaporator technologies, as it enhanced the machines precision and helped deliver product quality. Standardizing on a midrange Rockwell Automation solution, which shares the same EtherNet/IP communication network and is entirely programmed through the Rockwell Software RSLogix 5000 software environment, allowed CFT to save design time, to minimize programming efforts and to provide its customer Titan with improved extraction yield and mixing accuracy, with easier troubleshooting operations and with optimized energy consumption. CFT s customer is now better able to process a wider range of products, find the best possible combination of speed, paddle inclination and centrifugal force, adjust parameters according to the product being processed and to the desired characteristics of the refined puree, yet minimize product waste and oxidation. The RSLogix 5000 environment helped us to ease line testing and validation and to increase flexibility for future changes in Titan s line. Furthermore, the midrange automation solution from Rockwell Automation allowed us to take advantages of the EtherNet/IP communication network, which connects directly to drives, I/O modules, controllers and HMI stations in the line, Gozzi explains. The local service and the availability of spare components offered by Rockwell Automation were other key elements that make a difference in our cooperation with the provider, too. Using a Zenith Chrono combined with a Mixflow evaporator with a Rockwell Automation midrange platform, our customer Titan Frozen has also been able to gain a larger market share in just one year, satisfying the most sophisticated requests of its end-customers, Mario Gozzi concludes. For more information, contact: CFT S.p.A. Mario Gozzi, Sales Area Manager Phone: Titan Frozen Phone: Allen-Bradley, CompactLogix, FactoryTalk View SE, LISTEN. THINK. SOLVE., PowerFlex, PanelView Plus, Rockwell Automation, Rockwell Software and RSLogix are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVA Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication OEM-AP420A-EN-P February 2015 Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.
10 Solutions in Action Elmar offers various filling machines, with over 100 different models from seven to 72 stations For more than 40 years, the Elmar brand has been well known in the food, beverage, pharmaceutical and cosmetics industries. Incorporated in 1972, the company, headquartered near Buffalo, New York, has become one of the largest manufacturer of filling machines in the world. Allen-Bradley CompactLogix programmable automation controller Allen-Bradley PowerFlex 525 variable-speed drive family Elmar offers various filling machines, with over 100 different models from seven to 72 stations and volumes ranging from 1/2 oz. (15 ml) to 5 Imperial Gallons (22.7 liters). We are filling a very wide range of products including nearly every kind of solid particulates up to water - except aerated liquids, Ingmar Mallis, managing director of Elmar Industries, the European subsidiary based in Neuss, Germany, reveals. Various control and drive systems are installed in the Elmar machines, with respective overall solutions being custom-designed, depending on specific needs. The Monoblock is a machine combination, where the filler and closer are mounted on one frame and are jointly driven and controlled by, for example, an Allen-Bradley CompactLogix programmable automation controller (PAC), which is also responsible for the NCNF (No Container No Fill) functionality. In operation the filler valve remains closed when there is no container available to be filled.
11 A Monoblock can be used, for example, for the hot-filling of apple sauce. The short distance between the filler and closer stations largely prevents the plastic containers from deforming during hot-filling, explains Ingmar Mallis, describing the advantage of this design. The system can also address other dangerous situations, thanks to the Allen- Bradley SensaGuard non-contact safety interlock switches, which feature the latest generation of RFID technology for coding and inductive technology for sensing. Another device provides additional safety in the Elmar Monoblock: an absolute value encoder from Rockwell Automation helps to set the filling volume automatically. The machine operator puts in a certain weight or volume, e.g. 270 ml, and the encoder automatically adjusts the volume respectively, the managing director of Elmar Europe gives another example of the user-friendly Monoblock features. During filling itself, two Allen-Bradley PowerFlex 525 frequency converters define the right setting or the desired transportation, filling and closing speeds. Depending on the customer and their specific needs, we cooperate with various automation technology suppliers. And as our company s roots are American, it s clear that we prefer intensive cooperation with Rockwell Automation, particularly in the USA. Even more so when this global player supplies us with innovative drive, problem-solving competence and great support, Ingmar Mallis praises the technology partner Rockwell Automation. The values themselves are entered into an Allen-Bradley PanelView Plus graphic terminal via keyboard and/ or touchscreen and routines are stored for simplifying the control of the overall production procedure. This means certain programmes and procedures are available at a push of a button, such as the setting of various filling volumes or container heights, etc., Ingmar Mallis explains. For more information, contact: Elmar Europe GmbH Phone: Fax: Allen-Bradley, CompactLogix, LISTEN. THINK. SOLVE., PowerFlex, PanelView Plus and Rockwell Automation are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication OEM-AP424A-EN-P February 2015 Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.
12 Solutions in Action The IceCon range uses a variety of Allen-Bradley products to control the machine s concentration system GEA Messo PT is a globally recognised technology supplier and plant constructor and was formed by the merger of GEA Messo GmbH and GEA Niro PT B.V.. With offices in Duisburg, Germany and s- Hertogenbosch in The Netherlands, its core businesses are solution and melt crystallisation together with freeze concentration. Allen-Bradley CompactLogix programmable automation controller The company is particularly well known in the coffee industry, but it is also attracting a great deal of attention from other markets as its technology can be used for wine, beer and cider, dairy products, citrus fruits & vegetables and meat, fish, herb and vegetable extracts. In a nutshell, GEA Messo PT makes crystals. In the freeze concentration process these are ice crystals. A typical example would the concentration of coffee by gradually changing the water in the coffee into ice and then removing it using a special separation column, leaving concentrated coffee behind. This is an extremely effective way of making coffee concentrates without losing any aromas, like you would with evaporation processes. The company s freeze concentration machines comprise the crystallisers, which let the crystals grow to the right size and quality and the separators (wash columns). Around these there is peripheral equipment for cooling, feed tanks, CIP tanks, pumps, piping and product storage. Allen-Bradley PowerFlex 753 with HMI display Using its chemical equipment range, the IceCon also makes crystals, but from a variety of chemicals instead. The chemicals exhibit a very wide range of melt/freeze temperatures from -40 to 140 C and, as opposed
13 to the freeze concentration process where the end product is the concentrate not the water, in the case of the chemical process, the very pure separated crystals are the desired end product. According to Jan van Esch, Head of Sales at GEA Messo PT: With its innovative design, our IceCon freeze concentration machine has revolutionized the freeze concentration method, reducing the costs for businesses while still maintaining an excellent product quality. Its design is much simpler than earlier freeze concentration designs. Consisting of only one crystallizer and one wash column the process of concentrating products is reduced to one single stage. The IceCon range uses a variety of scalable products from Rockwell Automation to control the machine s concentration system; these include an Allen-Bradley CompactLogix programmable automation controller, Allen-Bradley PowerFlex 753 variable-speed drives and an Allen-Bradley PanelView Plus HMI. These machines can then be scaled and adapted to suit the local infrastructure of the end customer, with the control infrastructure becoming embedded in the overall plant-wide solution. The combination of the machine s innovative design and the advanced automation infrastructure means that GEA Messo PT has developed a solution that offers the lower energy consumption, thanks in part to the use of PowerFlex variable speed drives. It also offers continuous operation, with no need for intermediate cleaning and low operating temperatures, meaning it can be used on temperature-sensitive products and components with close boiling points. Its simplified design also results in lower maintenance costs, easier cleaning and a smaller footprint. Jan van Esch elaborates: The biggest advantage of the system is that we make a concentrate that is keeps all the quality of the starting products. An added advantage is that due to the low temperatures involved, bacteria don t grow and we only have to clean the machine once every three weeks instead of once every day. With regards to the use of automation products from Rockwell Automation, Jan van Esch explains: We have been able to streamline our design process and reduce our programming efforts, both of which have resulted in reduced overall engineering time, which in turn has saved costs and reduced mistakes. Testing and validation is also simpler. Our customers have also seen multiple benefits, including reduced training, reduced energy consumption and shorter installation and start up times. For more information, contact: GEA Messo PT Jan van Esch, Head of Sales Phone: Fax: Allen-Bradley, CompactLogix, LISTEN. THINK. SOLVE., PowerFlex, PanelView Plus and Rockwell Automation are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication OEM-AP425A-EN-P March 2015 Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.
14 Solutions in Action The MPRD exploits an advanced integrated automation and motion solution from Rockwell Automation Haas-Mondomix B.V. is a market and technology leader for aerating, depositing and extruding of fat creams, chocolates and dairy products. For more than 40 years, the company has been offering know-how and machinery for the processes in the baking, confectionery and dairy industries. Depending on the application, these plants can also include state-of-the-art cleaning and sterilization solutions. Allen-Bradley ControlLogix programmable automation controller Founded in 1978 as a Dutch family business, Mondomix entered the market with know-how in the field of continuous aeration systems. In 2002, Mondomix became part of the Haas Group where already a significant know-how existed in the field of mixing and kneading of creams, doughs and batters. Today, Haas-Mondomix, based in Almere, in The Netherlands, supplies the confectionery, bakery, dairy and non-food market segments in more than 50 countries with machines and technology for dosing, weighing, (pre) mixing, aerating, kneading, depositing processes. The company s customer list reads like a who s who of major household brands, including Mondelez, Nestlé, Pepsico, Bimbo, Lotte and Orion. Allen-Bradley Kinetix 6000 servo drive The company s new MPRD (Multi Piston & Rotary Depositor) is a piston depositor where each nozzle is fed by its own piston. This feature offers new ways for different fillings in different industries and makes the MPRD a one-of-a-kind solution for the wafer, chocolate, biscuit and confectionery industry and is of interest to the catering and dairy industries too.
15 Two X-Z portals form the base of the machine, each with its own servomotors and drives. The MPRD is mounted between/on top of the portals and connects them mechanically to each other. The servo motors of both portals are geared in a master/slave configuration, which provides the synchronization of the X-Z movement. Each nozzle is fed by its own piston and is closable at the tip One of the biggest advantages is the very accurate dosing weight. With a high accuracy per deposit, the MPRD ensures highly stability and constant product quality. The depositor can run at high speeds, a speed which is beyond the average speed on the market and offers the possibility of achieving the amount of throughput normally seen on two depositors. Due to its specific design, the MPRD can deposit aerated and even highly aerated masses by keeping the whole system under pressure, producing fancy and extraordinary products. The MPRD exploits an advanced integrated automation and motion solution from Rockwell Automation in order to achieve these impressive performance characteristics. The machine has an Allen-Bradley L71 ControlLogix programmable automation controller (PAC) at its heart, working in conjunction, via and EtherNet/IP network, with a number of Allen-Bradley Kinetix 6000 servo drives. These drives control a number of different servo motors models (depending on the power needs). Completing the infrastructure is a variety of digital and analogue I/O and an Allen-Bradley PanelView Plus 1250 touch panel HMI. Using this configuration, the MPRD can traverse with the product and it is this feature that helps the machine to achieve its impressive higher capacities compared to other technology on the market. It is also possible to add Y-axis movement to the MPRD to deliver crosswise motion for even more machine flexibility. In full configuration the machine can have up to 10 servomotors and associated drives. According to Mr. Raphael Jiraschek, Director Sales & Marketing at Haas Mondomix B.V.: The first machine we developed for a customer in South America who specified Rockwell Automation components. This was a benefit for us because we had already used Rockwell Automation PACs on other machines. It is easy to expand the number of servo motors and drives depending on the machine configuration and thanks to the software options commissioning is faster. We are considering using the Allen-Bradley Kinetix 5500 drives in the future, in order to minimise cabling and to be able build a more compact cabinet. For more information, contact: Haas-Mondomix B.V. Mr. Raphael Jiraschek, Head of Sales & Marketing Phone: Fax: Allen-Bradley, ControlLogix, Kinetix, LISTEN. THINK. SOLVE., PanelView Plus and Rockwell Automation are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVA Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication XXX-XX123A-EN-P MONTH 2015 Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.
16 Solutions in Action Frosto machines are designed for continuous freezing, aerating and mixing of ice cream Ice Group is an industrial ice cream machinery manufacturer, which also offers filling machines to other food production fields, including dairy, fishery, meat and confectionery industries. Allen-Bradley ControlLogix programmable automation controller Allen-Bradley CompactLogix programmable automation controller The company s experience, aligned with its openness and its ability to quickly recognise its customer s needs creates the basis for very successful relationships. This is reflected in its mission, which is to help its customers react quickly and precisely to changing market needs, with close cooperating for the good of the final product. Established over 20 years ago, ICE Group offers what it believes is probably the broadest range of machines for ice cream production in the world and can boast over 900 projects deploying dozens of machines types. With 90 employees, including 10 full-time design engineers and seven software specialists, the company can not only programme machines in-house but also offers a remote support function.
17 Many of the machines in the company s extensive range deploy advanced automation solutions from Rockwell Automation. One example is the Iglo Line tray tunnel, a complete and universal line for ice cream production. The end products from this machine can be in a variety of forms and includes frozen and packed products, such as stick ice cream, balltop cones, sandwiches, stickless products, etc. The Iglo Line uses Allen-Bradley ControlLogix or Allen- Bradley CompactLogix programmable automation controllers (PAC) for the primary control functions. These, in turn control a number of Allen-Bradley Kinetix 6500 servo drives and PowerFlex 753 and 525 variable-speed drives. The automation and motion infrastructure is completed with Allen-Bradley PanelView HMIs, a Stratix managed Ethernet switch for networking functionality and Guardmaster safety relays. Complementing the Iglo Line is the MASTER Fruit feeder a machine designed to add solid ingredients or suspensions of solid ingredients to the ice cream produced on continuous freezers. Typical ingredients include fresh or candied fruits, raisins, nuts, almonds, biscuit pieces or frozen chocolate pieces. This machine also leverages a Rockwell Automation control infrastructure and deploys an Allen-Bradley MicroLogix 1100 controller, a PanelView Plus HMI and PowerFlex 523 variable-speed drives. The company also supplies a range of continuous freezers, under the Frosto brand, which are designed for continuous freezing, aerating and mixing of ice cream. Fabricated primarily from stainless steel, these machines come in a number of variants, but all models leverage a variety of Allen-Bradley products, including MicroLogix 1100 controllers, PanelView Plus HMIs, PowerFlex 523 variablespeed drives and Stratix 2000 managed Ethernet switches. Through its use of Allen-Bradley products from Rockwell Automation, ICE Group is seeing a wide range of benefits including scalability and interoperability. The use of Ethernet as a networking solution also cuts wiring and installation times. Rockwell automation is also able to offer 24/7 worldwide support meaning that customers also see benefits, while enjoying advantages inherent with the worldwide acceptance and deployment of Rockwell Automation technology. For more information, contact: Ice Group Sp. z o.o. Mariusz Goik - General Manager Phone: Allen-Bradley, ControlLogix, CompactLogix, Guardmaster, Kinetix, LISTEN. THINK. SOLVE., MicroLogix, PowerFlex, PanelView Plus, Rockwell Automation and Stratix 2000 are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication OEM-AP428A-EN-P March 2015 Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.
18 Solutions in Action The MARIN hygienic intermittent cartoner provides a unique combination of hygienic features with impressive accessibility, product versatility and flexibility With production locations in Wijchen, in The Netherlands and Mississauga, Canada and offices in Bangkok, Thailand and Singapore, Langen Group is a packaging equipment solution provider committed to offering reliable standard and custom packaging machinery for cartoning, case packing and palletizing. It has great depth of experience in the development of a wide variety of cartoners, case packers and packaging systems, as well as offering expertise in complete system integration and standardised products. Allen-Bradley GuardLogix programmable automation controller Allen-Bradley PowerFlex variable-speed drives Over the past decade, the Langen Group has become an advanced solution provider, developing standard equipment, while specialising in custom projects. In the last 25 years it has installed over 4,000 machines and systems, including projects ranging in value from a hundred thousand dollars to those in excess of $10 million. Today, in close co-operation with its world-wide customers, it continues a tradition that results in a reliable and robust machine build that uses the latest packaging technology and intelligent engineering to quickly and accurately place our customers product into cartons, trays or cases. Customers include global, regional and local key players in food, spirits, personal care and consumer products. The company s MARIN hygienic intermittent cartoner provides a unique combination of hygienic features with impressive accessibility,
19 product versatility and flexibility. Equipped with a Rockwell Automation Integrated Architecture production control & information system, the machine comprises an inclined infeed conveyor, a collation and counting unit, a bucket conveyor and solutions for carton erection, carton loading and carton closing. The Rockwell Automation Integrated Architecture control solution covers all disciplines on the machine and does so over a single Ethernet/IP network. The automation solution includes an Allen-Bradley GuardLogix programmable automation controller (PAC), Allen-Bradley POINT I/O, an Allen-Bradley Kinetix motion solution and Allen-Bradley PowerFlex Drives. Completing the automation solution is an Allen-Bradley PanelView Plus touchscreen HMI. All industrial components, including circuit breakers and contactors are also from the extensive Allen-Bradley range and adhere to local regulations as these machines are sold and installed globally. Especially suitable for location after a single sachet, stick pack or pouch-making machine. The MARIN is capable of handling 800 sticks per minute or 400 sachets per minute. From a physical design standpoint, customers will appreciate its small footprint, its hygienic principles coupled to impressive accessibility; all from a machine that promises unsurpassed end product quality and real value for money. Langen Group extensively uses Allen-Bradley programmable automation controllers (PAC), Allen-Bradley Kinetix servo drives, Allen-Bradley PanelView HMIs, motor controllers, I/O devices, signalling devices, safetyrelated products and sensors. Jos de Boer, Director Global Marketing, explains the reasoning behind the deployment of products from Rockwell Automation: There is a global acceptance of Rockwell Automation products and this has enabled Langen to provided Allen-Bradley products to a wide variety of customers. Our customers are also benefitting from eased maintenance and troubleshooting, including remote maintenance, reduced training time, reduced changeover time, improved personnel/machine safety and minimized installation and start-up times, he adds. As a result, by using Langen equipment with Rockwell Automation controls, customers have been able to lower their manufacturing costs and improve production efficiencies. For more information, contact: Jos de Boer, Director Global Marketing Langen Group Phone: Allen-Bradley, GuardLogix, Kinetix, LISTEN. THINK. SOLVE., PowerFlex, PanelView Plus and Rockwell Automation are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVA Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication OEM-AP421A-EN-P February 2015 Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. Printed in the EU.
20 Solutions in Action The D-Series HFFS machine has been conceived by PFM to be an easier to use, integrated and highly efficient solution PFM Group is an international industrial group comprising twelve companies. Since its foundation in 1964, the Group has met all the flexible packaging requirements of the food and non-food industries, as chemical/ pharmaceutical and cosmetic ones. Allen-Bradley CompactLogix programmable automation controller Allen-Bradley PowerFlex 525 variable speed drives Headquartered in Torrebelvicino, in the province of Vicenza, the Italian Group designs and manufactures different types of packaging solutions: horizontal flow-wrappers, vertical form fill seal machines (VFFS), multihead weighers, automatic lines for the handling and packaging of bakery and confectionery and horizontal form fill seal packaging machines (HFFS) for the production of stand-up pouches. Our machines can be customised accordingly to specific packaging applications needs and produce a wide range of innovative and flexible packaging formats: open/closed, stand up, pocket bags and pouches, Andrea Fioravanti, R&D and Sales Director, PFM Packaging Machinery SpA, says. High flexibility and rapid format change, as well as patented sealing units and unparalleled performances for high productivity, mark PFM machines in the packaging world. The D-Series HFFS machine has been conceived by PFM to provide an easier to use, integrated and highly efficient solution to form, fill, seal and handle flat and stand-up packages for solid, granular, powder and liquid products. The machine consists of three modules, each of them having a specific function, and it is based on a Full Side Access concept, which allows the operator to enter the machine s perimeter and to reach all the components directly. Its three main functions forming, filling and sealing are accomplished by modular mechatronic devices, which can be easily extracted and inspected. The cleaning operations for the hygiene of the machine are simplified too. In addition to modularity, complete access and
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