VFFS Application Solution

Vertical Form Fill And Seal MachineSolutions for Advanced, Customized And Stand-Alone Machines

Sensor DetectsEnd of Roll

Detecting Overtravel of Tension Arm

Detecting Jam at Outlet

Missing Lug Check

Detecting Registration Mark to Synchroniuze Sealing

and Cuting OperationsEdge Detection(centering of film)

Cross sealing jaws create top and bottom seals in the pouches, and cut the filled pouch from the empty pouch.

Product enters the system through the forming tube.

Vertical sealing bars seal the edges of the film tube together.

Low friction rollers guide the film to the forming area.

The forming collar shapes the flat film into a round film tube.

Film transport belts pull the film through the forming area.

Machine/OEM Challenges• Material splice and film roll placement.• Film tension and gripping control.• Unique mechanical designs for different products.• Adjustable sealing pressure for different films and product sizes.• Grip control / slippage.• Proper force applied to the seal without energy waste.

Development Tools• Design productivity tools –Standard and reusable software

modules, AOIs, Motion Analyzer, Safety Automation Builder.• Modular code and HMI screens compliant with industry

accepted standards.• Integrated Architecture® offers a scalable, multi-discipline Logix

platform in a single programming environment.• Standard, off-the-shelf components.• Engineering expertise and support to help decrease time-to-

market.

Advanced MachineTypical Architecture

• Modern Human Machine Interface – ability to access PDFs and videos.

• Servo for faster changeover. • Variable Frequency Drive on integrated architecture with

cost effectiveness. • Reduction of panel space – I/O outside panel.

Packaging Speed > 80 Packs Per Minute

Network EtherNet/IP™

Controller CompactLogix™ L2

Variable Frequency Drive PowerFlex® 525

Servo Drive Kinetix® 5500

Synchronous Motion Up to Four axes

Studio 5000 Logix Designer® Power programming which allows program designs to be modular for easier programming and higher equipment safety. It saves significant engineering time, enables faster startup, and commissioning.

Optimized electronic CAM profiles motion control systems may ensure smoother machine operation and enhance machine mechanical life.

Optimal machine speeds by using motion sizing tools - Motion Analyzer.

Diagnostic information regarding Servos available on Human Machine Interface.

Programmable for constant seal-time for any machine speed.

Dynamic change of machine speed and corresponding sections synchronize with Controller Master reference.

Application program based on Pack ML State Model.

Higher machine speeds by optimization of cycle.

Studio 5000 Logix Designer®

Stratix™ Switch EtherNet/IP

Kinetix®5500 Servo Drives

CompactLogix™ L2 Controller

Unwinder

Film Feed

Sealing Jaw

PowerFlex® Drive

Filler

Jaw Unit Up/Down

PanelView™ Plus 7Human Machine Interface

Customised Machine – Typical Architecture

• Food grade servos and wash-down I/O for better sanitation.

• Single network based control architecture.• Motion Analyzer – Advance Motion Design tools

that improve performance.• Faster development cycle reduces time to market.

Packaging Speed > 100 Packs Per Minute

Network EtherNet/IP

Controller CompactLogix L3

Variable Frequency Drive PowerFlex 525

Servo Drive Kinetix 5500

Synchronous Motion More than 16 axes

Scalable control with a single programming environment with integrated motion instructions.

Higher capability and scalability with up to 30 I/O modules and 16 motion axes.

Integrated recipe management recipe controls allow companies to sidestep the repetitive process of tuning machines during a line change by saving and managing multiple settings.

Common Human Interface platform and networking services.

Built-in security capabilities support security standards, particularly ISA SP99. Collaborate with IT security specialist company such as Cisco to leverage on their expertise.

Safety enabled throughout.

Studio 5000 Logix Designer

Stratix Switch EtherNet/IP

Kinetix 5500 Servo Drives

Compact logix L3 Controller

PanelView Plus 7Human Machine Interface

Film Feed

Sealing Jaw

Jaw Unit Up/Down

Rotary Disc Filler

Filler Nozzler

PowerFlex Drive

Unwinder

Common programming software Connected Components Workbench™ software for Micro800®, PowerFlex (AC Drives), PanelView™ 800.

Advanced Motion Control Supports up to 3 motion axes using Pulse Train Output.

Versatility of interfaces Up to 6 high speed counter inputs and up to 3 Pulse Train Outputs over embedded digital I/O. Up to 5 plug-ins and up to 4 expansion I/O modules.

High flexibility Plug-in and expansion modules allow you to optimize your machine cost by choosing performance and functionality specific to your machine needs.

Touch probe function Able to capture accurate registration position at high speeds with built-in hardware.

Stand-Alone Machine Typical Architecture

Connected Components - proven optimal configuration. Cost effective solutions. Reduced panel engineering enables a shorter time for wiring and thus improves machine assembly time. Availability of plug-in modules at the controller allow for expanded machine features and functions.

Packaging Speed < 80 Packs Per Minute

Network Modbus / Pulse Train Output

Controller Micro800® Family

Variable Frequency Drive PowerFlex® 523

Servo Drive Kinetix® 3 / Kinetix® 300

Motion Up to 3 axes

Micro850

IN

OUT

0 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17

20 21 22 23 24 25 26 27

18 19

0 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19

POWER

RUN

FAULT

FORCE

COMM

Connected Components Workbench Software

Discrete/ Analog

PowerFlex 523 Drive

USB

EtherNet/IP

PanelView™ 800Human Machine Interface

Micro850® Controller

Film RegistrationSensor

Film Feed Encoder

Auger Feed

Film Pull

Cross Jaw

Film Unwind

PTO

PTO

PTO

Material Feeding

1

Filling of Materials

Vertical Sealing Web

Pulling

2

Sealing and Cutting

3

Supporting Your Business Every Step of the WayAt every stage in the life cycle of your machines, Rockwell Automation is your collaborator. From design to build to operation and maintenance, you can count on the continuum of Rockwell Automation resources.

By taking advantage of our products and services, you can lower your Total Cost to Design, Develop, and Deliver®, while improving your time to market. You will be better equipped to react quickly to change, increasing profits and attracting new customers with

high-performance and innovative machines. Whether providing you with single components, entire systems or specialized consultation or trying to achieve sustainable production initiatives, our goal is to offer solutions on a personalized level.

For More Information:Call a Rockwell Automation sales office or an authorized distributor today or visit us online at www.rockwellautomation.com

Publication OEM-BR044B-EN-P – September 2015 Copyright ©2015 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Allen-Bradley, Connected Components Workbench, Compact Logix, Compact I/O, Kinetix, LISTEN. THINK. SOLVE., Micro800, Micro850, PanelView, PowerFlex , Rockwell Automation, Rockwell Software, Stratix, Studio5000 Logix Designer, and Total Cost to Design, Develop and Deliver are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVA. All other trademarks and registered trademarks are property of their respective companies.

For more information about our OEM Solutions, please visit: http://www.rockwellautomation.com/go/lit/oem