Improved safety and quality in the production of packaging thanks to dynamic fail safe controls

The setting and maintaining of high quality standards order to prevent further processing or distribution on the currently plays a central role in the production of packing market. There are numerous causes and types of error. with high output rates. This especially applies to packing Product residues in the machine, selection errors or required to protect and preserve health concerns, namely in misdirected base materials cannot always be identified with pharmaceutical and the food industry. However, mix-ups will the naked eye or basic sensors. Errors can occur at any stage also affect the production efficiency in less sensitive in the process, such as in the composition of contents, during packaging sectors and will also lead to angry complaints. For primary packing (e.g. blister packs), during secondary packing this reason Baumer hhs has developed and implemented their in cartons, when enclosing written information or during own range of sensor to monitor its systems and in addition labelling. Basic sensors do not offer adequate reliability for uses intelligent “processes” that will only allow the approval these demanding tasks as a failure or malfunction of the to be given once all quality criteria have been met without sensor leads to the failure in error detection.. Therefore, exception With over 25 years of experience, Baumer hhs is Baumer hhs employs process-integrated monitoring according the leader in the field of quality control in the production of to the dynamic fail safe principle. folding cartons and printfinishing.. Baumer hhs understand, beyond the just the secure switching Mix-ups are one of the typical problems encountered during of a sensor, the principle of fail-safe to be for each product as the production of packaging. Carton boxes, blister packs and being non-compliant until it has been unequivocally other containers are occasionally partially filled or filled with evaluated by the QA system to be without errors. Individual the wrong product or, in the worst case scenario, end up in detection stations are logically linked to each other so that if the hands of the customer/ consumer wrongly labelled. The a single error (no signal for good product) is generated by one consequences of such a mix up are more serious with medical of the detection stations in the link will prevent the overall tablets and other pharmaceutical products. Consumers trust product approval.that the packaging contains exactly what the label promises. In the case of a multi packing system made up of individual Even if a sensor fails and thereby cannot confirm good components with the incorrect or missing information leaflet product, the overall process remains faulty and leads to a insert can lead to a number of complaints. Recalls are not negative evaluation and thus to the removal of the bad only costly, but also damage the company's reputation in the product concerned from the production flow. This dynamic fail long term. safe principle has been used from the outset at Baumer hhs . and ensures a high level of safety and quality in all systems

used for the production of folding cartons and print finishing. Baumer hhs is a supplier to all leading manufacturers of

The GMP (Good Manufacturing Practise) guidelines apply to folding carton machines and is a market leader in folding the production of food, animal feed, pharmaceuticals and carton quality control.medical productions worldwide. Among other things, they require measures to be put in place to prevent cross-contamination and mix-ups. A foolproof method to prevent mix up is to physically separate the packaging process for All sensors involved in the checking processes (code reader, different products and also to schedule them for different glue application controls, position monitoring, area and times. This requirement is not only achievable in practise, but height determination) are linked by means of evaluation also would mean a completely separate packaging line for software. For this, the individual signals are logically linked every product and the use of a packaging line for multiple together and combined in an overall evaluation, which products would not be permitted. Most packaging machines ultimately generates the control signal for the rejection are specifically designed for multiple products as this will mechanism. As an integrated solution, the central controls result in high efficiency machine usage and justifies the return offer numerous advantages . Rejected parts can be removed on investment for expensive and elaborate solutions. in the optimum location in terms of production technology as

each part is individually recorded, identified and monitored throughout the entire process. It is not necessary to plan a removal mechanism for each sensor, nor to drag a defective

An alternative is provide precise and targeted monitoring of product along through further process steps. In any case, it is all process steps with the aim of detecting even the smallest unnecessary to stop production as a whole for the removal of deviations and errors and reject the affected specimen in faulty products and this is prevented by the clever integration.

High requirements due to GMP guidelines

Software for integration and quality control

The Baumer hhs fail safe principle

Improved safety and quality in the production of packaging thanks to dynamic fail safe controls

In addition, the quality can be recorded over long periods, multiple cycles or batches or various production processes by means of statistical methods. Continuous quality monitoring discovers the sources of faults in the system controls and shows optimization possibilities and the effect of changes in configurations and other measures. Glue application parameters can also be recorded, logged and optimized. Multi-terminal systems and an Ethernet network connection are available for large systems with multiple operating locations.

Baumer hhs relies on various sensors that are adapted for their respective tasks, including code readers for particularly high production speeds. Code reader are central for the identification, recording and tracking of all types of packaging. They enable quality to be verified and the whole process to be logged. Simply constructed codes can also be read at high speeds, requiring considerably lower amounts of investments, computing power and system resources than image processing methods. Vision sensors that work using cameras are employed in a targeted manner if visual checks, image comparisons, live images or image archiving are deemed useful. Particular attention is given to the user interfaces, which are incredibly easy to operate and are tailored to the respective application.

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Baumer hhs GmbH 4/2012