Overview
Starpak/Levy & Smith has long been known for manufacturing the robust Brandpak single-roll wrapping/shrink-wrapping machine. While the mechanical design served its purpose, Managing Director Steve Smith recognized the need for modernization to improve versatility and efficiency.
The Challenge
The original machine relied heavily on mechanical components, limiting its adaptability. To meet evolving industry demands, Starpak aimed to integrate synchronized servo and VFD control for unwinding, film feeding, cutting, indexing, and final wrapping stations.
The Solution
After evaluating various options, Starpak chose the LS GM4 PLC, featuring rack-mounted multi-axis positioning control. This system, combined with:
- Four Mecapion servo inverters
- Five LS open-loop vector inverters
provided enhanced control and flexibility for the Brandpak.
Anadigi’s Role
As the official LS agents, Anadigi played a crucial role in:
- Specifying and optimizing the correct PLC, VFD, Servo Equipment, and Planetary Gearboxes
- Ensuring the system met speed, torque, and acceleration requirements
- Supporting Starpak in making the transition to more advanced automation
Key Features & Enhancements
- User-Friendly Integration: The new system retained the intuitive feel of the original mechanical design while incorporating advanced profiled multi-axis parameters.
- Customizable Recipes: Different pack sizes and operational parameters were pre-programmed into the LS PMU-330BTE touch-screen HMI, allowing users to select preset recipes and even create custom ones.
- Precision & Synchronization: The mechanical gear drives were replaced with:
- Three Mecapion servo motors coupled with HPB high-precision planetary gearboxes
- Directly coupled servo motor for the cutter blade, eliminating the need for a gearbox
- Encoder integration on the in-feed conveyor for synchronized movement across all axes
Results & Benefits
The upgrade resulted in significant improvements in:
- Smoothness and operational silence
- Flexibility and ease of setup
- Production tracking and fault analysis via the HMI display
The new Brandpak has been enthusiastically received by end users, who have praised its quiet, smooth, and efficient operation. Moreover, the increased versatility has enabled Starpak to process a wider range of pack sizes within the same machine geometry.
Ongoing Innovations
Starpak and Anadigi continue to refine the system, pushing the boundaries of efficiency and automation in packaging solutions.