Recently, we had the pleasure of hosting Sam Anderson, applications engineer at Magnum Systems, on our podcast series called AIM for automate, integrate and manufacture. With his impressive background in mechanical engineering and experience with food packaging equipment, Sam provided some fascinating insights into some common misconceptions about packaging systems, especially those dealing with powders, pellets and flakes. And there are many myths out there to debunk, so let’s jump in.
The Fiction of the All-Knowing Equipment Manufacturer
One common myth in the industry is the belief that equipment manufacturers are experts and have all the answers. While manufacturers have extensive knowledge of system integration and their products, they can't foresee every variable. This is why a thorough discovery phase is crucial to understanding the customer's entire process, their likes and dislikes, areas for improvement and how best value can be added.
The One-Size-Fits-All Machine Fallacy
Another misconception is the quest for a one-size-fits-all packaging machine that can handle multiple ingredients or fill both bags and boxes. The truth is that different products have varying characteristics - some may be free-flowing while others are hard to move. Therefore, specific fillers must match a product's unique characteristics. While specific machines can handle different products, they may not do so efficiently enough, affecting the rate, throughput and accuracy.
The Lifetime Accuracy Expectation
Speaking of accuracy, many customers believe that once a machine is set up and calibrated, it should maintain its accuracy throughout its lifespan. Unfortunately, this isn't the case. External factors such as environmental conditions, operator errors and unexpected shocks can impact a machine's performance over time.
The Air Packer Dust Myth
One such misconception is that air packers create too much dust. Sam clarified while air packers do move products using air, if the movement of the material is contained, it won't generate dust outside of the package or the packaging machine. He stressed the importance of testing the product and designing the fill spout correctly to avoid dust leakage.
However, he cautioned that expecting a packaging system to be 100% dust-free is unrealistic. Although the equipment can be designed to minimize dust as much as possible, a completely dust-free environment is misleading.
The Valve Bag Auger Packer Myth
Another myth is that valve bag auger packers are suitable for all ingredients. Sam points out that this may not be the case, especially if high accuracy is required. Weight accuracy and product control can be problematic with these packers. If your material is expensive, a different solution may be needed.
The Automation Solution
Stepping into the realm of automation, many believe that automating their packaging processes will solve all their problems. While automation can alleviate issues like worker fatigue and improve morale, it introduces new challenges that must be considered. For instance, automated systems require regular maintenance and may need occasional replacements.
As Sam points out, "Automation can solve a lot of problems, but then they also need to have the foresight to think of, you know, the robot's not going to be perfect forever, so it's going to have to have some upkeep throughout the life of its service."
Evaluating the Need for Automation
So, how do you know if automating a packaging system is the right decision? Here are just a few things to consider:
While these benefits are attractive, it's essential to remember that automation is not a one-size-fits-all solution and requires careful planning and consideration.
As Sam explains, "Not one machine's going to be able to fill every kind of container. One machine may be able to fill all your products, but it won't be able to fill them all efficiently."
So, while packaging automation can provide numerous advantages, making informed decisions is essential. It's crucial to understand your specific needs, the characteristics of your products, and the capabilities and limitations of different packaging systems.
Automation and Job Creation
Sam also addresses the common misconception that automation takes away jobs. While it's true that robots can replace repetitive manual tasks, they also create many skilled technical jobs. From robot manufacturing, programming and installation to maintenance. Using robots opens up a new range of employment opportunities.
As Sam shares, "It's a lot cooler to have a lot of technically skilled employees than just manual labor."
He further emphasizes that automation has been a part of industrial evolution since the revolution, and robots are simply the next step in this process.
So, while myths surrounding packaging systems contain a hint of truth, it's essential to understand the specifics before making decisions. It's crucial to understand your unique needs, the characteristics of your products, and the capabilities and limitations of different packaging systems. As Sam suggests, reach out to experts like Magnum Systems to debunk these myths and gain more accurate insights. Contact us today to help understand your specific needs.
Listen to Sam's podcast episode.
In this latest podcast, Magnum Systems provides valuable insights into a technology set to redefine the manufacturing landscape. It offers a comprehensive overview of the features, benefits, and applications of pneumatic conveying, making it a must-listen for anyone involved in the industry, whether you're a seasoned professional in the manufacturing industry or simply curious about the latest trends in manufacturing. We hope you give it a listen soon.
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