Hugo Beck: Horizontal form, fill, and seal machines fully automated with SEW-EURODRIVE

Hugo Beck Maschinenbau GmbH & Co. KG:

• Headquarters: Dettingen/Erms, Germany
• Sector: Packaging industry
• Number of employees: 110
• Founded: 1955
• Application in the project: flowpack X horizontal FFS machine

• Packaging technology that is more sustainable
• Modular and hybrid flowpack solution that doesn't use compressed air
• Early warning for failure
• Energy management
• Packaging in paper-based materials and in air-tight film packaging

• StarterSET 616 for HFFS including MOVIKIT® Bundle FFS
• PES intelligent energy management system
• Stepper technology including I/O System
• HMI visualization (operator panel)
• MBM model-based monitoring, parameter monitor
• Digital twin for process monitoring
• Servo technology (servomotors, servo gear units)
• Recipe management
• Integrated safety and sensor technology (STO, SLS)
• Sensor technology for print mark detection

The horizontal FFS machine, which had previously been run on compressed air, was automated using the "StarterSET 616" basic package from SEW‑EURODRIVE, along with comprehensive extensions such as Power and Energy Solutions and safety technology. As a result, it was possible to completely replace the pneumatic systems of the flowpack X with electrical actuators and extend the machine with intelligent energy management. The result is a machine with extremely low energy consumption. Perfectly coordinated software and hardware packages make the StarterSET a fully comprehensive automation solution.

Intelligent energy management
Combined with the MOVIKIT® software modules from SEW-EURODRIVE, the new energy storage system makes intelligent energy management possible. This makes the power supply more stable and helps bridge brief voltage dips. Peak loads are also reduced. One particular advantage is that the horizontal FFS machine is brought to a controlled stop in the case of longer power outages. As a result, the flowpack X can still be used when the local power grid is instable or even when a power outage is expected. Reducing peak loads also has another benefit, as the developers were thus able to significantly reduce the cross section of the power cable compared to the previous model. The machine's connected load and overall energy consumption have also dropped considerably

• StarterSET 512 for HFFS including MOVIKIT® Bundle FFS
• MOVITRAC® advanced compact frequency inverters
• Stepper technology including I/O System
• 230 V AC single-phase current connection
• Servo technology (servomotors, servo gear units)
• Recipe management directly in the controller
• For paper packaging, up to 150 cycles per minute
• Sensor technology for print mark detection

Electrical actuators take the place of pneumatics
Previously, motions such as cutting and clamping in the flowpack R packaging machine were implemented conventionally, using compressed air. However, stepper motors are now used for these purposes, and are controlled with the new bus terminal from the I/O system portfolio supplied by SEW-EURODRIVE. There is therefore absolutely no need for pneumatics. Replacing the actuators that were operated by compressed air also eliminates the associated maintenance requirements. The horizontal FFS machine from Hugo Beck is now easier to integrate into the production environment and offers more flexibility in this regard, too. Furthermore, energy costs are lower with this model.

Development and startup times cut
The key to speeding up development was to use a StarterSET, which is a fully and perfectly coordinated basic package of software and hardware "made by SEW-EURODRIVE". Despite the extensive reconfigurations, the development and startup times for the packaging machine were reduced by two months, taking them down to the absolute minimum.

• Development and startup time cut
  by 2 months thanks to pre-selected basic package
• Bridging of voltage dips
  for up to 9.5 seconds without line voltage
• Controlled cycle stop in case of power loss,
  thanks to Power and Energy Solutions
• Reduction in connected load
  from 32 A to 16 A
• Reduction in overall energy consumption
• Compressed-air-free operation
  thanks to stepper technology including I/O System
• Integrated temperature control
  in MOVI-C® CONTROLLER UHX65