Packaging Solutions That MatterKollmorgen Motion Control Technology and Co-Engineering for Measurable Results

K O L L M O R G E N

Perfecting the PackageAs an OEM, you know there’s nothing simple about making the perfect package. You must:

•Engineerautomationprocessesthatdifferentiateyourmachinefrom the competition

•Ensureareliablesupplyofmotionsolutionsthatmeetyourmachine’s unique functional requirements

•Managecostpressurestokeepyourmachineaffordablewhilemaximizing your margins

•Orchestrateperfectmotionacrosseverymachineprocesstoachievethehighestpossiblequality,flexibilityandthroughput

Kollmorgen understands the challenges you face. As the world’s leadingmotionexpert,weofferbest-in-classsolutionsproventoincreasemachineadaptability,availabilityandthroughput.Toreducedevelopmentcycles,time-to-market,commissioningtimeandoverallcosts.Andtoenablenewlevelsofpackaginginnovationandquality.

Weprovideallthemotionsolutionsandexpertiseyouneed. That’s the perfect package.

Kollmorgen co-engineering brings measurable success

Morethanasolutionprovider,we’reco-engineeringexpertswith unmatched insight into the packaging industry’s technical challenges and market requirements. Beyond optimizing technical performance, our co-engineering teams help you manage machine lifecycles and upgrades, operator training and safety, and customer serviceandsupport.Weevenenhanceyourbusinessprocessesthroughkanbansupplychainmanagementandjust-in-timedelivery.

We accept your challenges as our own. That’s the Kollmorgen co-engineering difference.

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Packagingexpertisetodeliverprovenbenefits

Real packaging applications, real results

The most important component of a successful packagingmachineisknowledge.Forming,filling,converting,wrapping,sealing,labelingandothercomplexpackaging processes depend on the ability to meet exacting performance parameters. Specialized solutions are required to comply with regulatory mandates for hygiene, quality and safety. And growing marketplace demands for new packaging styles and materials call forindustry-specificexpertisethatfewcomponentsupplierscanprovide.

With decades of experience, Kollmorgen’s packaging knowledge runs deep. We offer complete, interoperable motion solutions for the packaging industry including tried-and-trusted mechatronic systems, washdown-capablemotors,decentralizeddrives,high-performancecommunicationoptions,integrateddevelopmenttools and more.

Theproofisinthemachine,andwehaveachievedmeasurable results across the industry.

21% more throughput 23% lower material costs 52%higherprofits

PHARMACEUTICAL

42% lower energy requirements21%lessdevelopmenttime

FOOD AND BEVERAGE

37% more throughput 25% lower material costs33% longer motor life

FORM/FILL/SEAL

33% lower material costs21%lowerservicecosts100% pinch points eliminated

CONVERTING

28%higherproductivity23% less waste24% less programming effort

HIGH-PERFORMANCE CUTTING

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A50-axisblisterpackagingmachineprovidesextremethroughput and a platform for the future

KOCH Pac-Systeme GmbH of Germany designs and builds blister packaging machines for batteries, contact lenses, household goods and many other consumer products. Among KOCH’s most complex and ambitious projects is a packaging machine designed and built for one of the world’s largest toothbrush manufacturers.

With 23 axes for blister production and 27 axes for packaging processes, the machine creates 12 toothbrush packages per cycle at a rate of 20 cycles per minute. That’s 14,400 packages per hour, with each package holding 4 toothbrushes – a total of more than a million toothbrushes packaged for every18hoursofoperation.

A future-ready servo drive

Thishigh-performancepackagingmachineispartofaKOCHinitiativetoaddresscustomerdemandsforever-increasingproductthroughput,variety,sophisticationandquality.Totakeitspackagingplatformstothenextgeneration,KOCHneededadrivesolutionthatcouldpreciselycontrolhighlydynamicprocessesacrossmultipleaxes.Kollmorgenservodrivesprovidebest-in-classmotioncontrolalongwithseveralstate-of-the-artfeaturesthatadvanceKOCH’sstrategicgoals.Forexample:

•Highlyflexiblesupportforadvancedfieldbus,motorandsensortechnologies

•Integratedsafetyfunctions

•Functionsthatsimplifyfaultrecoverytominimizedowntimeandmaximizeproductivity

AdvancedcommunicationoptionssuchasCANopen® and EtherCAT® are providedthroughaninternalFPGA,soKOCHcansynchronizemultipleaxeswithaccuracymeasuredinmicroseconds,whileavoidingtheneedtopurchaseexpensiveoptioncards.

An affordable solution to a common problem

Oneissuethatoftenplaguespackagingmachinesisthedifficultyofre-referencingthemachineafterafault.Inthepast,KOCHhadtosavesensorpositionsonanexpensiveexternalmemorycardtoavoidtheneedforre-referencingafteranemergencystopduetoanoverrunofthemulti-turnabsolutevaluesensor.Now,theKollmorgenservodriveperformsthisfunctionwith no need for additional hardware.

For KOCH, Kollmorgen is the competitive edge

“TheKollmorgenservodrivemeetsourneedsforflexibleintegration,stabilityandimprovedproductionthroughputtimes,”saysJürgenWelker,KOCH’sheadofautomationtechnologyandservice.“Itstechnicalrefinementsproduceexcellentcontrolbehaviorandahighdegreeofautomation.”WithKollmorgentechnology, co-engineering and support, KOCH is building safer, faster, more flexiblemachinesthaneverbefore.Andlookingforwardtocreatingevenmoreremarkable machines in the years to come.

Kollmorgen’s Domain Knowledge Makes the Difference for High-Performance Packaging MachinesKollmorgenhasdeepexperienceandaconsistentrecordofsuccessinthepackagingindustry.Applyingourextensivedomainknowledgetospecializedapplicationchallenges,wehavehelpedpackagingOEMsaroundtheworldachievemeasurableresults.Thesepagespresentafewrepresentativeexamples.

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Kollmorgen’sservotechnologymovesmorethan4,000axesinPFMpackagingmachines worldwide

ThePFMGroupisaworldwidenetworkofsevencompaniesthatprovidesflexiblepackagingsolutionsforfoodandotherindustries.AnchoredbytheheadofficeofPFMPackagingMachineryinItaly,thegroupdesigns,producesandmarketsverticalform/fill/sealmachines,feedsystemssuchas automatic handling machines, accessories and parts for numerous machine processes, and complete packaging lines.

Production machines from the PFM Group are used to package pastries, cheeses,meats,vegetables,fruits,sweets,pharmaceuticalproducts,cosmetics and more. To handle all these packaging applications, the PFM Groupneededasupplierthatcouldprovidetheoptimumservoequipmentacrossaverywiderangeoftechnicalrequirements.BychoosingKollmorgen, the PFM Group has gained:

•Adaptability,withaccesstothewidestselectionofthemostversatileservodrivesandmotorsandstate-of-the-artintegrationcapabilitiestomeet any packaging need

•MoreefficientdevelopmentsupportedbyKollmorgen’spackaging-specificco-engineeringexpertise

•Improvedcustomerresponsivenessthroughourglobalproductavailabilityandkanban-basedmanagementpractices

Simplifying development of more capable machines

Kollmorgen’sproductflexibilitygivesPFMaffordablechoicesfordesignchangesandupgrades.Forexample,it’seasytoreplaceadrivecommunicatingoverCANopenwithadrivecommunicatingoverProfibuswithin the same product family, without replacing the axis wiring. And Kollmorgenco-engineeringremovesmuchoftheengineeringburdenandcost from PFM Group, helping speed the time to market for machines that are ideally suited to any application requirement.

Ensuring a reliable supply to maximize useful life

Kollmorgenprovidesleanmanufacturingandjust-in-timedeliverytohelpmeetthemosturgentdeliverydeadlineswhileminimizingwarehousestocks and costs. The PFM Group can depend on access to the parts it needstokeepitsmachinesproductive,andtoaddnewfunctionalityasthepackagingmarketevolves.

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Kollmorgenservotechnologydriveshigh-throughput, high-quality packagingforawidevarietyofnoodleand snack products One of South Korea’s largest and most rapidly growing companies is a producer and packager of instant noodles and rice products, snack foods, fruitjuicesandbottledmineralwater.ThecompanyoperatesseveralKoreanfactoriesaswellasproductionsitesinChina,Japan,DubaiandtheUSA,leadingtheKoreanmarketandservingapproximately80additional markets worldwide.

Sustaining its growth while maintaining the highest quality standards was no longer possible with the antiquated mechanical packaging system the company had been using for its multipack packaging applications. A new servo-basedmotionsolutionwasneededtooptimizepackagingquality,flexibilityandspeed.Kollmorgenwaschosenovercompetingsuppliersforthe easy commissioning and the high stiffness, accuracy and reliability of itsservosolution.Nowthecompanyisextendingitsmarketleadwitharevitalizedpackagingsystemthatbenefitsfrom:

• Ahigh-speed,coordinatedmotionsolution. Compared to competing suppliers, the Kollmorgen solution offers greater torque density and more precise positioning, enabling the packaging machine toachieve60%higherproductivity.

• Effectiveco-engineering.Kollmorgen’s co-engineering team helpedthecompanydesignamoreversatileandeffectivemachine, without the expense, delay and supply problems of a highly customized solution.

• Superiorprogrammingforsuperiorresults.Kollmorgen’s fully integratedprogrammingtoolsandpackaging-specificprogrammingexpertisehelpedthecompanyachievethebestpossibleperformanceresults, faster.

Afield-installableupgradekitbringshigher performance and longer machine life After 20 years on the market, the world’s best-selling bagmaker was due for a third-generation performance upgrade. Kliklok-Woodman, based in Georgia, USA, turned to Kollmorgen to help co-engineer a high-performancereplacementforthemachine’soutdatedservodrivesandmotors.Thegoalwasnotonlytosignificantlyincreaseperformanceand reliability for the newest models, such as the Polaris E, but also to provideanupgradekitthatcouldbeeasilyinstalledinexistingmachineson-sitetoextendtheirlifecycleandtaketheirperformancetonewlevels.

Once Kliklok-Woodman presented their problem, Kollmorgen co-engineeringdeliveredtherightsolution.Kollmorgenprovidedthe rightknow-howtodeveloptheentirekitinclosecollaborationwiththeKliklok-Woodmanengineeringandcustomerserviceteams.Theupgradekitprovidescompleteservocontrolandcostslessthanabasicreplacementmotoroftheoriginaltype.TheverysuccessfulPolarismachineseries,whichhavebeeninproductionforyears,arenowtakingadvantageofKollmorgen’sfullyintegratedservotechnologytoprovide:

• Reduceddowntime. The new components can be installed, tuned and maintained in a fraction of the timepreviouslyrequired.

• Improvedperformance. TheupdatedPolarisprovidesincreased throughput and reliability with reduced noise andvibration.

• Alongerlifetime.With the Kollmorgen upgrade kit, packaging machine operatorsaresavingon costs and gaining assurance that their machineswillgivethe bestpossibleservicefor years to come.

K O L L M O R G E N

Higher performance means higher sales thanks to an affordable stepper solution MatrixPackagingMachinery,Inc.basedinSaukville,Wisconsin,USA,neededanaffordablesteppermotoranddriveforitsverticalform/fill/seal machine to be sold in Asian markets. But competing on price alone wouldn’t be enough. To win sales, the machine would need to make a real difference in product quality and throughput. That’s why Matrix chose Kollmorgenoverothersuppliersthatcouldmatchtheprice,butnotthetorque, precision and consistency of our stepper solutions.

According to project Engineer Mike Krummey, the choice of Kollmorgen wasadecidingfactorinhelpingMatrixachieveitsprimarygoalforthemachine: higher sales. “All three axes in our machine are now operated withastepdriveandmotorsfromKollmorgen,”Krummeysays.“Ourchoicehassolvedalltheproblemsregardingtorque,precision,quality,serviceandsupport.Thecostsmetourpriceexpectations,andthepackage also came with additional functions that translated into higher salesfiguresimmediately,reflectingcustomersatisfaction.”ForMatrixPackaging,Kollmorgenstepdrivesandmotorsoffer:

•Lowcostforhighperformance.TheKollmorgendriveincorporatesmicrosteppingtechnologythatdeliversprecisionandperformancecomparabletomanyservosystems,butatasignificantlylowertotalcost.

•Lessdowntimeandwaste.The Kollmorgen driveincludesanopenloopstalldetectionfeaturethatcandetectafilmjamorbreakandstop the machine. Matrix markets this as its “worry-freepackage,”andithelpsminimizedowntime and scrap without the need for a separate sensor.

•Morepowerandperformanceinasmaller,moreaffordablepackage. Kollmorgen motors lead the industry in torque density. So Matrix machines gain all the power and performance they need without the expense and space of a larger motor.

A67%fastermachineopensupnewmarkets with larger customers Profitpackaging,Inc.wantedtoboosttheperformanceofitsflagshipmachineinordertoincreaseitsmarketshare–anditsprofits.Thecompany, based in Warsaw, Missouri, USA, manufactures note and label applicators for the newspaper and commercial printing industries. Profitpackaging’sgoalwastoincreasethroughputfrom600to1000labelsper minute to in order to reach publications with a larger circulation than its existing client base.

TheKollmorgenteamhelpedProfitpackagingreplacetheP3NoteandLabel Applicator’s stepper system with an AKD™servodriveandAKM™ servomotor.Althoughthenewservosystemitselfcostsmorethan thesteppersystem,thecostwasjustifiedbytheeliminationofsensors,gearboxesandothercomponentsthatcouldberemovedbecausethey werenolongerrequired.Now,thecompanyoffersasignificantlyfaster, morescalablelabellingmachinethatoffersseveralcompetitiveadvantages:

•Reducedcomplexityandincreasedperformance.The AKD’s advancedautotuningalgorithmcompensatesformismatchedinertia in the labeling machine, eliminating the need for a gearbox. As a result, the machine operates with greater accuracy and requires less maintenance.

• Fasterthroughput.Becausethenewservosystemoffersmuchgreaterbandwidththantheprevioussteppersystem,itprovidesquickeracceleration and deceleration with greater positioning accuracy, so the machinecanrunatleast67%faster.

• Lowerwarehousingcosts.The new design eliminates the need forspecialized,machinedparts.Soinventoriescanbesmaller,andprocurement is quicker and easier thanks to the dense Kollmorgen supply network.

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K O L L M O R G E N

Motion is at our core

Weunderstandthepackagingindustry’smostdifficultmotionchallenges.Onecommonexampleishigh-speedregistration.Servodrivesmustbeabletoachievethefollowingoperatingcharacteristicsinordertocoordinatehigh-speed motion based on registration marks:

•Drivesmustbeabletorecordandconvertregistrationmarksinlessthan5millisecondstoavoidunacceptableoffsetting.

•Acorrectivemovementmusttakeplacewhilestipulatingacamprofilewithin 15 microseconds.

•Toachievecorrectresults,positionerrormustnotexceed0.03mm.

•Drivesmustoperatewithidealsynchronizationatthousandsofcycles perminutetokeepprocessesmovingaccuratelyatfullspeed.

The performance of the motion control system is a key factor in allowing drivestomeettherequireddynamicsandresponsetimes.Incombinationwith the high dynamics of the motor-controller combination, the motion controlsystemmustbeablecalculatetargetvaluesforalldrivesat4kHzintervals(every250microseconds)andtocommunicatethesevaluestothedrivesviahigh-speedEtherCAT.

Kollmorgen understands strict motion requirements like these, and has the expertise, optimization tools and integrated automation components to reliably meet them. Kollmorgen Automation Suite™providesafullyintegrateddevelopmentplatformdesignedtomeettheneedsofhighlydynamic applications while simplifying programming, ensuring quality and improvingmachineperformancebyasmuchas25percent.

Kollmorgen Automation Suite combines all the main functions of a high-performancecontrolsystem,includingmotioncontrol,PACandHMI. Itcanbeusedtodevelopandsimulatehighlycomplexprocesses across as many as 128 axes. The suite is optimized for machine performanceandprogrammingflexibility,offeringbothPLCopenprogrammingbasedonIEC61131-3andourinnovativePipeNetwork™ graphicalprogrammingenvironment.

It’sjustoneexampleofthemanysolutionsweoffertodrivethe highest possible machine and business performance for packaging machine manufacturers.

Motion control expertiseFormorethan70years,Kollmorgenhasprovidedmotionsolutionsthatmakeindustrialmachinesmoreproductive,preciseand powerful. Successful packaging applications require high performance motion control solutions for demanding machine requirements such as:

• Highlydynamicaccelerationanddeceleration

• Fast,intelligent,precisemotioncontrol

• High-torqueapplications

• Coordinationandsynchronizationofmotionacross multiple axes

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Supply chain optimization

Long-term success and growth of your business depends on reliable product availabilityandyourabilitytodeliverontimeandonbudget.Morethanmotion control components and expertise, we offer co-engineering support to help you manage your supply chain and control costs. Through kanban supplyprogramsandthecontinuous-improvementmethodsoftheDanaherBusinessSystem,weprovideshortleadtimesandreliableon-timedelivery.Youcancountoncontinuoussupplywhileminimizingyourinventoryrequirements. Your costs are lower as a result, freeing up working capital soyoucanbecomemoreresponsiveinamarketenvironmentwhereproductavailabilityisadrivingsuccessfactor.

Aftermarket revenue protection

OurcustompartnumbersandOEMpartprotectionservicesensurethatyoureceivefullaftermarketrevenuesthroughoutthelifecycleofyourmachine.Wecanevenadministertheprogramonyourbehalfthroughourglobalsalesandsupportnetwork.Insteadofcompetingfortheaftermarketservicebusiness for your own machines, you maintain the control you need to ensurecustomersatisfactionandcapturealltherevenueyou’reentitledto.

Machinery improvement services

Ourglobalteamofautomationdesignexpertscanevaluateyourexistingmachines and your next-generation designs, recommending strategies to improveperformanceandaddfunctionality.Kollmorgenbringsyearsofexperiencetoform/fill/seal,blisterpackaging,flexoandgravureprinting,cartoning,corrugating,andfoodwrappingapplications.Inparticular,ourstrong focus on web-based motion control can make a real difference in yourmachinedesign,generatingmeasurablebenefits.

Machine lifecycle enhancement

Marketsgrow,technologyevolvesandcustomerexpectationschange.We can help you keep pace, with solutions and expertise that keep your machinesfullyproductivethroughouttheirlifecycle.Wecanevencreateupgrade paths that enhance your machine’s throughput and functionality, extendingitslifecycleintoanewgeneration.Thebenefit:nosurprises,andnoneedtodeployyourvaluableengineeringresourcestosupportamachinenearing the end of its lifecycle.

CommercialservicesYour enterprise relies on more than your machine. Kollmorgen’s commercialservicesenhanceourbest-in-classmotionsolutionstocomplete the co-engineering experience. Components that perfectly fityourmachine’stechnicalrequirementsareonlythebeginning.Wealsotailorourcommercialservicestoperfectlyfityourbusinessmodelandenhanceyourcompetitiveposition.

InnovativeProductsand Co-Engineering Expertise for a Complete Solution

K O L L M O R G E N

ServoDrivesKollmorgendrivescombineperformance,flexibility,andeaseofusewithKollmorgenAutomationSuiteandallKollmorgenservomotorsandlinearpositioners. Multiple communications bus options, plug-and-play commissioning, exclusivePerformanceServoTuneralgorithm,multiplefeedbackoptions,andindustry-leadingtorqueandvelocityloopbandwidthprovideyoutheflexibilitytobring the right solution to your machine.

DecentralizedDriveTechnologyKollmorgen’s AKD™NearandIntegratedservodrivesprovidelowertotalsystemcostsandsavespaceinmulti-axisOEMpackagingmachinesbyreducingcablingrequirementsandcabinetsize.TheAKDNearDriveprovidesallthebenefitsofanIP65protecteddecentralizeddriveinstalleddirectlyonyourpackagingmachinewithoutanyde-ratingofthemotorordrive.

IndustrialControlsKollmorgen Automation Suite™dramaticallyshortensdevelopmenttimewhileincreasingmachinethroughputbyasmuchas25percentormore.OurexclusivePipeNetwork™providesadrag-and-droprepresentationofyourmachinetoenablequick, error-free programming of complex, multi-axis motion.

Kollmorgen Automation Suite™

AKD™ Near Drive

AKD™ Drive

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Kollmorgenprovidesthelargestselectionofthemostinnovativemotors,drives,controls,gearheads,andlinearpositioners, including a complete range of products adapted specificallyforthepackagingindustry.Ifwedon’thave exactly what you need, we can co-engineer components toyourspecifications.

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Linear Positioners and GearheadsKollmorgen linear positioners are perfect for mechatronic solutions and mechanicalapplicationwitharangefrom20N(5lb)upto25kN(5600lb) ofthrustandprecisionfinerthan0.1mm.Kollmorgengearheadswithhelicalgearing, gear crowning and TRUE Planetary™ construction create the highest torque, smoothest operating gearhead on the market.

The Kollmorgen DifferenceBetter motion differentiates your machine through new packaging capabilities, higher quality and throughput, reducedriskandafastertimetomarket.Kollmorgendelivers:

•Notjustmotorsanddrives–fullyintegratedsolutions co-engineeredfortrueinnovation

• Global design, engineering, manufacturing and support, with lead times among the lowest in the industry

• Unparalleled market insight coupled with the product breadth,depthandflexibilitytomeetcustomerneeds

•Aprovenhistoryoffinancialstabilityandmarketsuccess

•Reliable,long-termsupplyandengineeringservicessoyoucanbuildabettermachinetoday,keepitproductive,andcontinue to enhance it far into the future

Find out how we can work together through co-engineering to differentiate your machine.

Contact Kollmorgen at 540-633-3545 or request information from packaging@kollmorgen.com

Servomotors AKM™foodgradeandwashdownservomotorsprovidehygienicsolutionswith

all the performance of the high torque density AKM.

AKMservomotorsprovidethehighesttorquedensity,andthelargestnumberofco-engineeredofferings(500,000+partnumbersandgrowing),allavailablegloballyforrapiddelivery.

Cartridge DDR™technologysimplifiesmachinedesignbyeliminating wearingpartsandimprovingservoperformance.

DirectDriveRotary(DDR)motorseliminatetransmissioncomponentstominimize maintenance and increase performance.

KBM™framelessmotorsprovidethebestmechanicalfitfortough applications that require the smallest for factor.

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Stepper MotorsKollmorgensteppermotorsprovideprecisemotionwithouttheneedforfeedbackdevicesandnear-servoperformancewhenusedwithaKollmorgenmicrosteppingdrive.Ourlargeselection,withstandardconfigurationsavailabletomeetyourapplication’sspecificvoltage,speedandtorquerequirements,givesyourmachineasimple,cost-effectivealternativetopneumatic,hydraulicandservosystems.

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©2011 Kollmorgen Corporation. all rights reserved. KM_BR_000130_Reva_EN Specifications are subject to change without notice. It is the responsibility of the product user to determine the suitability of this product for a specific application. All trademarks are the property of their respective owners.

About Kollmorgen

Kollmorgen is a leading provider of motion systems and components for machine builders. Through world-class knowledge in motion, industry-leading quality and deep expertise in linking and integrating standard and custom products, Kollmorgen delivers breakthrough solutions that are unmatched in performance, reliability and ease-of-use, giving machine builders an irrefutable marketplace advantage.

Forassistancewithyourapplicationneeds, contact us at: 540-633-3545, packaging@kollmorgen.comorvisit kollmorgen.comforaglobalcontactlist.

Kollmorgen203a West Rock RoadRadford, VA 24141 USAPhone: 1-540-633-3545Fax: 1-540-639-4162

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