PETplanet Insider Vol. 23 No. 12/22 www.petpla.net 21 PETINAR by light-weighting, Recycling while using new PCR resins and Reusing by producing returnable packages. In addition, Sacmi fulfils this objective by using rPET material in different packaging applications, by developing tethered caps which enable an easier recycling of the whole package. Returning to his question of how to translate digitalisation of closure manufacturing into a real economic advantage Iacopo explained it as generating, elaborating, and profiting from data. During the presentation of a compression moulding machine (CCM) for closures, shown at Drinktec, Iacopo explained how the data is generated. Sacmi has developed a new combination of hardware and software, called SmartPack, which generates the data. The hardware and software are designed to ensure fast, precise action on the production process. These features maximise flexibility, real-time precise adjustment during production, stated Iacopo. The SmartPack focuses on four aspects of the production process: pellet insertion, the material & thermic control and finally the hydraulic system. With SmartPack it is possible to get a graphic representation of the dose of molten material inside the mould during the production process. Through this and other devices the time for pellet cut and insertion adjustment is reduced by more than 50%. Process drifts are detected very quickly so that the operator can react before a problem occurs. It is also easy to detect any wear, because of the multiple checks enable the operator to predict wear related behaviours. This has an impact on the maintenance time of the machine, which schedule is adjusted according to sensors feedback, ensuring both process consistency and the longest life of the hardware in use. The second focus point is the material control where incorrect resin is detected. An algorithm programmed by Sacmi observes the change from one resin to another in real time. If the wrong resin is in production, the system issues an alarm first, then it stops the machine. The SmartPack also supports an assisted colour change, suitable for existing receipes and if the colour is already in the hopper. Soon as the colour change is started, the system starts deriving the previous colour and model in both the CCM press and the vision inspection system, until the new requested colour is detected, to be suitable for standard production. For a powerful and long-lasting machine system, it is necessary to ensure the good health of the hydraulic parts. In this case, the SmartPack checks the physical and chemical features of the oil, which, as Iacopo mentioned, is the life-blood of the machines. In addition, the hydropneumatics accumulators precharges are continuosly so that the operator can plan corrective actions in case of a loss of pressure. Thus, a huge package of data is produced, but how is it to be evaluated? The collected data is stored in the cloud and analysed using AI. For example, a comparison of two resins can be made for a desired application: which material is better suited, which resin saves material and engineering costs as well as machine maintenance. Iacopo concluded by summarising the features of the SmartPack care maintenance program; 22% less labour time, 20% fewer spare parts needed, and 55% more production efficiency is achieved over a two-year period, according to a case study, which resulted in 20,000€ savings for the customer. www.sacmi.com The last lecture in this PETinar series dealt with a new process during the production of preforms. Mr Jordan Robertson, VP of Business Development and Marketing at StackTeck presented the new PiCool technology, an advanced post mould cooling system for PET preforms. Jordan started by explaining existing conventional post mould cooling technology: In the preform moulding industry, there are 2 main technologies used for the cooling/transfer stations. Both provide internal convective cooling by introducing a stream of air into the preform, either by blowing air in, or in a reverse manner by drawing air out. Both methods have their advantages, and both offer improvements to cycle time and preform quality. So the question is: why did StackTeck set out to develop a new method that we now call PiCool? Because, said Jordan, we recognised thermal variations. We found through thermal imaging that preforms often have significant temperature variations, both lengthwise and circumferentially about the preform. This became a limitation when trying to accelerate cycle times, as certain sections of a preforms’ surface were hotter than others. These hot areas could result in deformation issues, contact marks, or sticking to one another. We then embarked on a project to improve the cooling uniformity at the final stage of moulding. With the PiCool concept the air stream enters the preform in a spiral direction, continuously wrapping around the internal surface picking up heat, then exiting through a centre exhaust tube. The spiral trajectory of the air stream forces the air over the internal curvature of the preform (concave shape). The concave shape creates extreme turbulence of the air flow: an effective “scrubbing” of the inner surface layer of the preform takes place, this creates a uniform cooling profile both axially and circumferentially and significantly improves the heat transfer to result in a colder preform temperature. There have been tests of the PiCool system on a 96 cavity 4-stage assembly in Netstal PET-Line 4000 system (side-entry). These tests show that with less cycle time and less temperature the same temperature is achieved as standard. www.stackteck.com With this lecture we closed the series of PETinars for this year with thanks to all our speakers and participants as well as our sponsors! Finally, a reminder that the lectures as well as the presentations are available online at: https://petpla.net/2022/09/06/ review-technical-highlights-drinktec2022/?s=
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