"Don't look at this iron lump silently, there are 72 changes hidden inside." In the assembly workshop of PLY-PACK Packaging Machinery Factory, Master Zhou, who has worked for 23 years, chatted with us while adjusting the equipment. As the most experienced debugging technician in the factory, he has assembled at least thousands of pillow packaging machines by hand.
1. Fast: "Light Kung Fu" in the servo control system
The new technician Xiao Wang was squatting beside the equipment to record the operating data: "Customers used to complain that it took a long time to change specifications, but now our pillow packaging machine can automatically switch by pressing a button." He was talking about the servo control system that our factory upgraded this year. This system has increased the packaging speed by 30%. The most amazing thing is that it can compensate for the tension of the film material in real time during the continuous packaging process. When we renovated the production line for a biscuit factory in Tianjin last month, even 0.5 cm irregular cookies could be wrapped steadily.
2. Accurate: "Embroidery Kung Fu" of packaging accuracy
Director Li of the pharmaceutical workshop came to the technical department to thank him: "Your pillow packaging machine can solve a big problem!" It turned out that the sterilization cotton pads they produced required the packaging sealing line error to be no more than 0.3 mm. The visual inspection module we added to the equipment raised the qualified rate from 88% to 99.6%. Master Zhou revealed the secret: "The key lies in the synchronization of horizontal and vertical sealing. Our cam structure is made according to the precision of Swiss watches."
3. Stability: "A Hundred Changes" of Film Material Adaptation
The pillow packaging machine being debugged will be sent to Yunnan. The customer wants to package the local specialty flower cakes. Zhang, the technical team leader, specially demonstrated the unique skill of "cold and hot": from glutinous rice paper that wrinkles easily when heated to aluminum foil composite film that becomes brittle at low temperatures, the equipment can automatically adjust the heat sealing temperature. "We just did a minus 20¡æ environmental test for a customer in Northeast China last week, and it still worked!"
4. The "unique secrets" of the masters
There is a true story circulating in the factory: on the eve of the Mid-Autumn Festival last year, a mooncake factory faced the risk of suspension of production due to a temporary change in packaging size. We sent three masters with pillow packaging machines to the door overnight, debugging and teaching on the spot, and completed the switching of 20 specifications within three days. The customer later sent a banner with eight big characters on it: "Be prepared for battle, every style is in place".
At present, the R&D department is preparing another big move - implanting AI algorithms into pillow packaging machines. "In the future, the equipment will be able to learn the best sealing and cutting parameters by itself, just like a master like Lao Zhou has a digital apprentice." The factory manager said as he turned on his mobile phone. In the video, the new model was processing soft wet wipes packaging bags, and the sealing trajectory was more stable than the master's hand.
Standing on the observation deck on the second floor of the workshop and looking down, more than 20 pillow packaging machines were lined up and ready to go. The sunlight passed through the gaps of the horizontal sealing knife holder, casting neat spots of light on the conveyor belt. In a trance, it seemed as if countless products were carrying the imprint of PLY-PACK and heading towards a broader world.
