SubscribeA new Packaging Control system is being highlighted by Cobalt IS at PPMA 06. On the stand, a full packing line demonstration shows secure processes for batch set-up and operation, to ensure packaging accuracy.
The increase in short run, customised packaging has highlighted the opportunities for error on a standard packing line, where disparate equipment and separate set-up processes result in mistakes being made.
Automating the line set-up and monitoring process, supports the introduction of secure practices, reducing the risk of costly rejection, redress and fines.
Cobalt IS are demonstrating a safe set-up process, using biometric authentication, where the whole process is controlled at a single point, the Cobalt Sentinel. At the start of a batch, the selected packaging is checked to the coding schedule, recipe management system or production schedule, using either local or corporate data.
On approval, the Cobalt Sentinel sends the required set-up parameters for this product to the inkjet coding, validation and print and apply labellers positioned on the line, in preparation for production. This prevents operators having to move to each device on the line to individually enter data, reducing the risk of inconsistencies and errors.
In process, every pack is checked against the expected value for this batch. Incorrect product is rejected, without interrupting the flow of production. All rejects are counted, and the intelligent reject bin warns when it is almost full. When repeated incorrect packaging is detected, alarms are initiated, and the line is stopped. As the problem is resolved and the line is reset, a valid reason code is recorded in the history log.
Best Before and Use By dates are passed to coding equipment during batch set-up, allowing for offset calculation and incorporating day and date change practices for each product. All changes to settings are recorded, with user name, date and time.
Secondary case labelling is also controlled from the Cobalt Sentinel, with label design and variable data being selected to correspond with the product being packed. The Cobalt Sentinel is able to access parameters across the corporate network, to ensure standardisation of layout and content. All outer case barcodes are verified to ANSI equivalent standards on printing and validated on application, with full datalogs being retained to confirm production activity.