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Hopak Machinery Implements Smart Solutions to Develop Intelligent Packaging Machine
- Significant space requirements – traditional packing machines are limited by hardware
- Increased costs
- Lack of data collection and integration platforms, failing to provide data for equipment operation and production
- One automated packaging production line to package three different arrangements of products
- Estimated 80% reduction of downtime and 30% of floor space
- Market leader of smart and intelligent horizontal packing machine
- Enhanced competitiveness and market share of Taiwanese machinery equipment factories in international market
The comprehensive smart mechanical solution helps Hopak Machinery overcome space, cost and data collection challenges.
Challenge
Three major pain points in traditional packaging machines
Based on the current usage of packaging machines, there are three major pain points:
1. Significant space needs
In terms of space requirements, traditional packaging machines are limited by the hardware they use. A single device can only package one type of product. If there is a need to switch packaging specifications, such as packaging other products or the same product in different styles, the machine can only be stopped to change mechanical parts, adjust gear ratios, and be reprogramed. This may take at least four hours to complete.
Consequently, factories usually set up two to three packaging production lines to ensure production efficiency.
This not only increases costs, but also requires a larger factory space, especially for automated feeding packaging lines, which require even more space, significantly impacting factory space layout and workflow planning.
2. High costs
The mechanical structure of traditional packaging machines is relatively complex, leading to high maintenance costs.
Additionally, production lines heavily rely on manual adjustments and operations, resulting in high labor demands and costs. With experienced workers retiring and less young talent joining the workforce, the skills shortage further exacerbates costs.
3. Difficulties in data collection
Traditional packaging machines typically lack data collection and integration platforms, failing to provide data on equipment operation and production. This limitation hinders the development of applications such as production history tracking, equipment optimization, and process enhancement.
Solution
Comprehensive smart machinery solutions driving upgrade of packaging machines
Hopak Machinery introduced a comprehensive smart mechanical solution integrating the following solutions from Rockwell Automation: iTRAK® intelligent track systems, Emulate3D™ digital twin software, and FactoryTalk® Optix™ software platform.
The iTRAK system enables the team to adopt a modular design, allowing integration into existing packaging machine mechanisms used by Hopak Machinery, thereby avoiding significant changes in mechanism design. They can also integrate lug chain push rods and smart belt conveyor belts to expedite and streamline equipment assembly, reducing the need for staff.
Emulate3D can simulate the operation status of the production line digitally, meaning that the packaging machine automatically adjusts and operates after switching to different work orders. It also calculates the benefits of enhancing production efficiency by replacing the original mechanism with iTRAK.
Finally, the FactoryTalk Optix software platform supports the storage and transmission of equipment operation and production information, providing the necessary data for the team to transform and improve operations in their factories.
The Rockwell Automation Global OEM Technical Consultant (GOTC) team provided comprehensive technical support to help Hopak Machinery tackle various challenges throughout the equipment development process.
“The GOTC team not only understands the operating principles and mechanisms of packaging machines, but also the usage requirements of manufacturing plants, and can assist in integrating iTRAK with peripheral components and existing systems to help Hopak Machinery improve its product transformation journey,” shared Rockwell Automation OEM customer manager Chun-Chieh Ou.
Result
The main distinction between the smart and intelligent horizontal packaging machine and the traditional packaging machine lies in the capability of iTRAK to automatically detect products and control the mover on the packaging machine independently. This allows for a reduction in the length of the automatic feeding conveyor belt, while simultaneously enhancing packaging speed and flexibility, leading to an estimated 80% reduction of downtime and 30% of floor space.
Moreover, when changing packaging specifications, there is no need to replace too many parts. An automated packaging production line can package three different arrangements of products, allowing a manufacturing facility to meet all packaging needs with just one packaging production line, which helps in optimizing factory space and increasing the operating rate.
“Traditional packaging machines are already in a ‘red ocean’ market. iTRAK allows Hopak Machinery to break away from the red ocean and enter the ‘blue ocean’”Shao-Kai Wei – Business Manager, Hopak Machinery
He believes that through the product upgrades, it opens new horizons for Hopak Machinery. The smart and intelligent horizontal packaging machines are not common in Taiwan. Hopak Machinery can be said to be a leader in the Taiwanese market. With increasing smart manufacturing demands to come, more manufacturers will inevitably require such smart machines.
Therefore, Hopak Machinery will be expanding the application scope of smart and intelligent horizontal packaging machines across fields such as medical, semiconductor, and electronic products, hoping to break away from the price competition of traditional packaging machines and retain its hold as a leader in the smart packaging machine market.
“Rockwell Automation will continue to develop more intelligent mechanical solutions in the future. We look forward to assisting more Taiwanese OEM factories like Hopak Machinery that are driving digital transformation, developing smarter machinery with greater production flexibility and data integration capabilities, enhancing the competitiveness and market share of Taiwanese machinery equipment factories in the international market.”Chun-Chieh Ou – OEM Customer Manager, Rockwell Automation
