On a snack production line, workers are struggling to change product specifications frequently - from 50g bagged potato chips to 500g family sharing packs, each time the packaging specifications are switched, the machine needs to be shut down for 2 hours to disassemble the mold and calibrate the parameters. With the commissioning of ply-pack's new generation of pillow packaging machines, such a scenario is being completely rewritten: tap the screen to select a preset solution, complete mold replacement and parameter synchronization within 10 minutes, and the production line is running at full speed again.
In the food, medicine and other industries, product packaging specifications are diversified and orders are fragmented. Due to the fixed structure and low changeover efficiency of traditional pillow packaging machines, enterprises frequently face the problem of waste of production capacity and rising energy consumption. To address this pain point, ply-pack launched an integrated solution of modular design + servo drive technology:
. Modular fast changeover system: Through standardized interface design, components such as molds, cutters, and conveyor belts are modularized. Operators only need to call pre-stored programs to quickly match packaging requirements of different specifications. Actual measurement data from a puffed food company showed that the changeover time was shortened from an average of 90 minutes to 8 minutes, and the annual production capacity increased by nearly 20%.
. Servo drive precision control: A five-axis linkage servo system is used to adjust the packaging film tension, sealing and cutting position, and temperature curve in real time. When packaging a 100-gram nut gift box, the equipment can automatically identify the difference in film ductility and control the heat sealing strength error within ±1.5%, completely solving customer complaints such as bag breakage and air leakage.
Unlike single equipment upgrades, ply-pack's solutions run through the entire production process:
·Material side: Jointly develop 0.08mm ultra-thin high-barrier film with suppliers, which is 18% thinner than traditional packaging film, and can save customers more than 120,000 yuan in film material costs each year (calculated based on an annual consumption of 30 tons of film per machine).
·Energy side: The intelligent temperature control system dynamically adjusts the heat sealing power according to the ambient temperature and humidity to avoid no-load energy consumption. After a dairy factory accessed this solution, the energy consumption of the pillow packaging machine decreased by 22%, saving 86,000 yuan in electricity bills annually.
·Operation and maintenance side: Remotely monitor the life of key components through the IoT platform, and warn of hidden dangers such as cutter wear and motor overheating in advance. With this function, a condiment company in Guangdong reduced the unplanned downtime rate from 4.3% per month to 0.7%.
In the context of the explosion of customized demand for e-commerce, this solution is becoming a weapon for enterprises to seize the market:
·Snack industry: With the help of the fast changeover function, a certain online celebrity brand can process 12 kinds of holiday-limited packaging on the same production line every day, and the delivery speed of emergency orders during the 618 promotion period has increased by 40%.
·Medical field: For special forms such as blister plates and granules, ply-pack uses customized molds + negative pressure adsorption systems to ensure that the position error of aluminum-plastic plate packaging is ≤0.3mm, which meets the requirements of GMP certification.
·Cross-border logistics: In order to meet the needs of international transportation, a shock-proof and cushioning packaging mode is developed, and an air cushion generation module is integrated in the pillow packaging machine, which reduces the damage rate of goods during transportation from 1.2% to 0.15%.
The sun shines through the top window of the workshop onto the pillow packaging machine that has just come off the line. The engineer is demonstrating the operation process on the control screen: the fingertips swipe across the three-dimensional visualization interface, and the running trajectory, temperature curve, and production capacity data of the packaging film jump in real time, like a precise digital ballet. As the "Confirm Optimization" button is pressed, the equipment automatically adjusts to the optimal operating state - this is not only a victory for technology, but also a deep response to industry needs.
