“Sustainability: the New Manufacturing Imperative” | |||||
|---|---|---|---|---|---|
THE CONFERENCE AT PACK EXPO PROGRAM-AT-A-GLANCE | |||||
TUESDAY, OCTOBER 16, 2007 | |||||
|
E-MACHINERY |
UPGRADING OPERATIONS |
BRAND PROTECTION |
PROCESSING |
CONVERTING |
8:30- |
Distance Learning and Control: Tips and Techniques for Economically Monitoring Remote Packaging Lines |
Lean Changeover |
The Main Event - Metal Detection vs. X-Ray; Which Contaminant Detection Technology
Will Win in the Long Run? |
The Benefits of Prepackaging Optical Inspection |
|
9:20- |
Tapping the Ethernet to Monitor Multiple Remote Packaging Ops |
Packaging Execution Systems (PES) - A New Way of Thinking About Packaging Operations |
Anti-Counterfeiting Options for the Packaging Process |
X-Ray Inspection - The Future of Processing |
|
10:10- |
KEYNOTE: | ||||
|
|
|
TRACK & TRACE |
MATERIAL ADVANCES |
|
11:00- |
Six Sigma and the World of Packaging |
RFID on the Packaging Level – How to Get the Chip on the Box! |
Signs on the Road to Sustainable Packaging: What to Ask for, What to Say and How to Do it |
||
11:50am- |
Automation Solutions for Changeover and Uptime Optimization |
Enhancing RFID Through Layering Other Technologies |
Achieving Greater Profitability and Sustainability in the Packaging Supply Chain |
||
LUNCH |
|||||
|
|
|
|
CONVERTING |
|
1:30- |
|
|
|
||
2:20- |
|
|
Web Coating - Expanding Packaging Applications Using Electron Beam Technology |
||
In his presentation, John Luke will discuss the important relationship between sustainable packaging and winning brands, and the strategic partnership between packagers and product managers that can help ensure generations of commercial, social and environmental brand performance. Today, discerning consumers are making more purchasing decisions based on evidence that a product or brand has been created with a sustainability ethic in mind. Mr. Luke will tell the audience why it is in their best interest for sustainability to flourish, rather than fade – and describe how sustainable packaging must go beyond compliance in order to enable winning brands to deliver on the stewardship promise.
Description: What does it mean to take time and distance out of operating, maintaining and fixing equipment? How can it be achieved? Surprisingly enough, a lot of “E-machinery” techniques are simple, added features to new automation technologies with minimal budgetary impact. The p resentation will include:
Description: We will present MachineNet, an Ethernet network approach, to provide complete communication in a multiple line system between each line and each machine to include both up and downstream interface with any location. A bakery line model with five wrappers will demonstrate machines that “talk” with a live demo to our show floor wrapper. The remote Dynamic Monitoring Communication (DMC) uses the latest electronic functionality for multi-machine integrated supervision, which allows any wrapper to monitor for the entire system with virtual redundancy from any location anywhere in the world.
Description: This discussion will educate attendees regarding E-machinery feasibility and installation. Presented topics include capabilities or limitations for E-Machinery, remote process monitoring, troubleshooting/repairing equipment via modems, qualifications for purchasing machinery, updating existing equipment, cost of updating existing equipment versus job-site service and, most importantly, the resources required to take advantage of time and cost savings associated with E-machinery. Case studies are reviewed, with particular applications discussed to help attendees apply information. This presentation will include handouts with presentation outline for notes; open forum discussion during presentation will provide attendees the opportunity to address their particular applications.
Description: The use of networking and remote diagnostics for equipment operation, maintenance and troubleshooting is becoming an essential part of increasing overall operational effectiveness. For a 24/7 packaging line, the cost of waiting for a service technician to arrive is substantial. With remote access, manufacturers’ technicians can access equipment through the Internet or a plant operator can download status information and email to appropriate personnel for immediate troubleshooting. Diagnostics can be done in real-time, even if the service person and equipment are thousands of miles apart. Production managers can use the same technologies to monitor equipment status to address issues before they halt production.
Description: Many companies focus on “quick” changeover. Unfortunately, “quick” often means trying to do the same old things faster. “Lean” changeover focuses on eliminating waste in changeover. This will take the form of wasted motion, effort, skills, paper, materials and product. Eliminating these will eliminate wasted time, resulting in faster changeovers. This presentation will provide a four-step approach to achieving lean changeover: 1) Eliminate all unnecessary tasks; 2) Externalize all possible tasks; 3) Simplify the remaining tasks; 4) Make all changeover adjustments quantifiable and repeatable. The presentation will include slides showing practical examples of each of the steps.
Description: A Packaging Execution System (PES) is a trend in designing packaging lines to capture performance/safety data from disparate automation and monitoring devices. It then synthesizes data into actionable intelligence and shares information for real-time decision-making at line, plant and enterprise levels. PES is repeatable on lines or plants as regulatory demands increase and higher levels of efficiency are expected. Systech will address how companies are investing in this new approach to their packaging operations; its implementation; and how it enables companies to provide protection, clarity and optimization to their business.
Description: Today’s packaging lines operate in a highly competitive global environment, necessitating efficiency and quality levels that, yesterday, were elusive goals. Many packaging companies are ISO-certified and, therefore, assume this will ensure these lofty targets will (somehow) be achieved automatically. This presentation shifts the focus from ISO-driven internal processes to the employment of product-driven Six Sigma methodologies, with concentration upon packaging production efficiency and quality. Attendees will come away with an understanding of the importance of statistically quantifying their packaging processes.
Description: Faster changeover and increased machine uptime are two areas where users of packaging machinery can still expect to see productivity increases. Industrial networking solutions will play an important part in this next step of productivity increase. The focus of this presentation will be on networking safety devices and demonstrating how this enhances flexible, high-speed packaging systems. Using this approach, users can perform changeover operations quickly. Better diagnostics of safety systems is expected to increase overall uptime.
Description: HACCP principles in the past 20 years have resulted in the deployment of tens of thousands of metal detectors in a wide variety of applications in food/packaging production lines. Unfortunately, these detectors only find metallic foreign objects and do not always offer the highest level of food safety. Advanced technologies like x-ray can offer a more complete inspection but are more complex and costly. So the question before many quality professionals and plant engineers is when and where to apply which technology. This presentation will provide some practical guidance.
Description: The presentation discusses utilizing advanced imaging technology combined with standard packaging processes to detect and prevent counterfeiting of packaged products. The process can be done on-line and in real-time using imaging technology. In addition, the presentation will include other new technologies, including micro markers that can be added to both the packages and products to detect and track products; invisible bar codes; and lenticular printing.
Description: RFID is an emerging technology to be used in volume for the identification and tracking of goods. For contactless communication with pallets, boxes and individual items, an RFID label is applied onto the goods. Due to an intended one-way use, the cost target for a smart label currently is five US cents or less. To achieve this ambitious goal, the development of novel manufacturing strategies for RFID products is of major importance. Several attempts are made to streamline the production process with the goal to create a smart label on the packaging level. The improvements in printing of conductive inks for antennae in combination with prepackaged RFID chips (so-called straps) open new opportunities to move from a relative costly slap-and-ship approach to an integrated smart label production process on the packaging level.
Description: Enhancing RFID through the layering of other types of technologies to ensure anti-counterfeiting protection and optimum safety in the event of an electronic failure.
Description: Optical inspection systems (“sorters”) have long been used for quality control in processing lines. As part of a new, emerging trend, these systems are being inserted into lines after processing and just before product packaging. A detailed discussion on the primary functions of optical inspection at this point in the processing line will be presented, including product safety, final quality control and the collection of product data for feedback control of upstream processes. The benefits of various optical inspection system types in the prepackaging area and in various food product applications will also be discussed, as well as the wide range of technologies available from cameras to lasers and belt sorters to channel sorters. In conclusion, implementation issues will be addressed, with a view to a fully automated factory of the future.
Description: X-ray inspection is the ultimate product integrity checking system for the food, beverage and pharmaceutical packaging lines. Our speaker will explain the technology and its specific application to these industries. Modern x-ray technology can identify metal, glass, stone, bone and dense plastic contaminants; inspect for missing or damaged products; and verify fill levels. All of this can be done in the final sealed product container - whether it is in foil, plastic or a card. It is reliable, safe and easy to use.
Description: As an EPA Performance Track company and manufacturer of some of the most environmentally friendly packaging materials available, Monadnock will advise brand owners on selecting, designing, printing and processing options to achieve the highest sustainability scores. What do PCW (preconsumer waste), FSC, Recycled, SFI, Green E, PCF and ECF mean? Attend this session and find out.
Description: This is a how-to presentation on achieving greater profitability and sustainability in the packaging supply chain based on Georgia-Pacific’s new Packaging Systems Optimization (PSO™) program. Emphasis is put on the importance of analyzing the complete packaging supply chain, beyond the package itself. This includes assessing cost savings and efficiencies and measuring sustainability from sourcing through distribution. The presentation will also cover the need to improve sustainability metrics in light of Wal-Mart’s packaging scorecard. Discover new methods for measuring sustainability and quantifying cost savings, and learn about a sustainable alternative to nonrecyclable, wax-coated boxes commonly used for produce and other perishables.
Description: A discussion of how to leverage recent “lean manufacturing” will be presented, including features of existing and new technology in surface treatment to increase production speed and reduce investments in labor and utility costs.
Description: This session will provide an overview of various applications using electron beam (EB) technology in the packaging market. The presentation will include new technical developments using EB curable inks, adhesives and coatings.
Description: This seminar will offer a review of the choices available when upgrading a coating line to meet the more demanding, changing and growing markets. It prompts a discussion regarding the reasons to change the coating head, the types of coating methods needed to manufacture present and future products, the coating head options available and the approximate cost to undertake the change.
Description: Is your tired old drying system limiting your production throughput? Are dryer operating costs sending your profits up in smoke? Are you experiencing product quality issues that have been traced to dryer performance? Is it time for a new dryer? Perhaps, but depending on the age and condition of the equipment, the nature and extent of the problems you are experiencing along with economic viability considerations, you may want to consider upgrading your existing system rather than replacing it. In this presentation, the author will discuss potential system upgrades, including air handling system modifications, control enhancements, nozzle replacement and other modernization options designed to increase line speed, eliminate costly defects, reduce energy costs or expand line capabilities without incurring the capital cost of a new dryer or coating line.
Description: Circonix Technologies recently delivered a completely integrated solution to upgrade and modernize converting machinery. The equipment required a complete control and automation overhaul, as well as mechanical modifications. This session will concentrate on the drive and control aspects of the process.
Description: On-line gauging for real-time process measurement and control continues to gain importance. The demand for increased functionality and higher quality in multi-layer films and coated web products is rising, resulting in more complex and costly structures. Layers and coatings are getting thinner, production runs are shorter and line speeds are increasing. To meet this demand and remain competitive requires an efficient process able to run quality product, within specification, from start to finish of a run. This cannot be accomplished with periodic lab sampling, since a defect caught in the lab may be hours old! Add requirements for proof of compliance, the ability to conduct effective product development and real-time process troubleshooting, then an on-line gauging system becomes a tool in this effort. The purpose of this paper is to discuss the applicable gauging sensor technologies and coating measurement techniques.
Description: This session will provide an in depth look at the use of UV coatings and UV processors in all realms of the converting industry. Highlights include a look at installations currently utilizing UV in the production of multiwall bags, flexible film packaging, preprint linerboard, folding cartons and laminations. Segments on the use of UV coatings in food packaging as well as a cost comparison of the UV process versus other drying options will be discussed.
Description: Adhesion of inks and coatings on polymer substrates is an issue faced by all converters. This presentation describes flame treatment and why it provides better results than other methods. Troubleshooting and problems are all discussed.