Electricity and Control May 2022

CONTROL SYSTEMS + AUTOMATION

Agile automation to support sustainable packaging Sustainability in the packaging industry is one of the key aspects in fighting the problem of plastic waste, its environmental impacts and, in turn, climate change.The challenges this presents require flexible and powerful automation technology. PatriciaTorres, Industry Marketing Manager Food and Commodities Solutions, Omron Industrial Automation Europe, here outlines some of the solutions the company offers.

I n times of increasing efforts to support sustainability in industry, it is essential to find ways to develop more en vironmentally friendly packaging, conserve resources, and make use of smart and more efficient production lines. Holistic concepts are needed. Take coffee capsules for example: users want a quick and easy way to prepare a fresh cup of coffee in the morn ing, but the popular disposable capsules represent a huge environmental burden. A more environmentally conscious consumer looks for coffee beans grown more sustainably or capsules produced in a more environmentally friendly way. Generally, people are more environmentally aware these days and they are looking for greener recyclable materials. Consequently, more sustainable manufacturing approaches are key. There is no question that too much plastic is produced and disposed of worldwide. Plastic production has in creased exponentially – from 2.3 million tonnes in 1950 to some 448 million tonnes in 2015, and this figure is expected to double again by 2050. Another problem is that plastics often contain additives to make them stronger, more flex ible, and durable. However, many of the additives extend the life of the plastic products to the extent that when they become waste, some estimates indicate they could take at least 400 years to decompose. In this context, the packag ing industry is one of the main contributors to this plastic glut, which urgently needs to be minimised. The industry faces the mammoth challenge of developing sustainable alternatives and minimising waste, and at the same time saving energy and using alternative energy sources.

Key considerations for more sustainable packaging

ƒ Reduce packaging material – not only in terms of vir gin plastics content in primary packaging, but also in the amount of protective secondary and final pack aging. ƒ Eliminate the need for single-use packaging; some strategies to address this issue start with increasing the use and scaling of reusable and refillable sys tems, or redesigning the package with alternative packaging materials that facilitate recycling, are bio degradable, compostable or have lower impact in the environment if they end up in the landfill. ƒ Packaging made from mono-materials is another ap proach attracting increasing interest in the packaging industry; they offer better recyclability but migrating to them can be a challenging process that requires strict process control. Often, packaging equipment needs to be adapted or customised to achieve an advanced form, fill and seal process that ensures the same package quality and performance. All these efforts to realise more sustainable packaging, need to be accompanied by a collecting infrastructure that enables a waste-free or low-waste future as well as building behaviour change among consumers, industry, retailers, and the entire circular system. New requirements for production facilities Reducing the amount of plastic used in packaging, espe cially if it is virgin plastic, can be facilitated by shifting from rigid to flexible packaging. Thinner walls, smaller sizes, narrower seams, and lighter weights also contribute to reducing the amount of virgin plastic used in the primary container. In addition, the use of mono-materials, paper-based and biopolymers, and a higher proportion of recycled material in main packaging, protective and transport packaging (primary, secondary and final packaging) is help ful. These changes have implications for processes and technologies on the factory floor. For example, companies need to check the compatibility of their equipment and adjust settings if necessary. Lines need to be flexible to change over to new materials. Linking and managing new machine-to-machine

To minimise plastic use in packaging, automation and robotics can assist manufacturers in adapting lines to handle new materials.

4 Electricity + Control MAY 2022