Profitable digitalization by SACMI#2: waiting for Chinaplas 2022
SACMI heads to Shanghai (National Convention Exhibition Center, 25-28 April 2022) to illustrate a complete 4.0 cap and preform line with unique features:
1 - the new CM-Flow extrusion unit on the CCM press range, which yields significant energy savings by boosting the quality and efficiency of the extrusion process.
2 - fast, carefully controlled systems that automate and speed up granulated color changeovers
3 – integrated CVS 360 systems for ‘all-round’ product inspection, with process feedback to extend vision system functions to process control.
These are just some of the characteristics of the 4.0 cap and preform lines SACMI will be showcasing at the international Chinaplas 2022 fair.
In this episode, we explore a specific aspect of the way SACMI cap and preform lines are being digitalized. The SACMI range combines advanced technology and control with the intrinsic advantages of the compression technology employed on CCM presses (SACMI, in fact, is the leading provider of cap manufacturing technology in China).
The result? A more sustainable, economical process with quick size changeovers, guaranteed quality at every stage and, above all, the option of upgrading product inspection to obtain automatic feedback-guided process control.
CM-Flow, the next-gen extruder. CM-Flow is the latest SACMI extrusion system; it feeds the resin needed to manufacture caps. The absence of motor-linked gearing ensures overall on-press electricity savings of up to 9%, giving process efficiency and quality a considerable boost.
Thanks to direct screw-motor connection, the line layout can be as compact as 1 meter. Also, the CM-Flow feeds a plasticizing screw with a diameter of just 35 mm, allowing the machine to process up to 200 kg/h of resin, the same as a conventional 75 mm extruder.
However, unlike the latter, the CM-Flow offers simpler, faster maintenance and higher extrusion process quality: the first SACMI customers to install this system have, resin type remaining equal, successfully reduced black spots by up to 50%. Caps produced with this system are also highly resistant to stress cracking, making it easier to manufacture lightweight caps. Note also that the extrusion process occurs at lower temperatures, reducing on-material stress and, therefore, increasing profitability.
Fast color changeovers. The SACMI 4.0 cap line is set up to ensure fast changeovers. Customer demand for rapid format and color changeovers is growing fast. So SACMI has responded with a line that allows the extruder to interface with the SACMI HERE control system.
In other words, color changeovers are controlled automatically by the MES (Manufacturing Execution System) which instructs the granulate feeder to load a specific recipe-related resin. The system (which also features automatic cleaning) only feeds the press when the loaded color and the recipe match: if they don’t, a warning is generated. This not only accelerates the process, it increases safety by preventing human error and, consequently, any incorrect production.
Computer Vision Software, 360° product (& process) control. SACMI has a unique capacity to design and deliver dedicated vision systems for each stage of both cap and preform production. The solution on show at Chinaplas consists of controls downstream from the press, where CVS systems inspect the entire surface of the cap, inside and out.
The following two checks are particularly noteworthy:
· anti-tamper band wing inspection with pericentric optics to identify even the smallest flashes
· detection of dishing/doming on the bottom of the cap.
In the SACMI range, the system’s primary task - to identify defects on the product - is accompanied by a secondary one: to provide the user with aggregated data that can be used to for real-time correction (or automatic optimization) of line production parameters. In fact, interpretation of the huge amounts of real-time data supplied by the system allows optimization of the entire production facility from a 4.0 manufacturing perspective. The outcome: higher quality and a faster return on investment.
Waiting 4 you at Chinaplas 2022! (SACMI booth 2.1F61)
Stay Tuned!
