When describing SOMIC’s latest generation of machines, “better is the enemy of good” comes to mind. The manufacturers from Amerang in Upper Bavaria debuted the SOMIC 434, a new machine for one-piece corrugated packaging using the wraparound concept of two-piece packaging solutions comprising a tray and cover and featuring new sorting and alignment technology for even greater flexibility in product grouping, at Interpack 2023.
Improving the integration of customer requirement
When describing SOMIC‘s latest generation of machines, “better is the enemy of good” comes to mind. With it’s all-new design, the 434-machine generation stays true to SOMIC’s philosophy. The underlying platform concept is new. This machine design allows for a wide range of sequencing options within the packaging process while maintaining a compact frame and small footprint. What exactly does this mean? The machine’s slim footprint and the linear arrangement of stations between its carton forming and closing modules make it ideal for integration into filling and packaging line concepts. “We have often learned from our discussions with clients that the linear station arrangement fits better into the plant layout than our earlier rectangular machine model,” explains Josef Bliemel, director of systems engineering, who played a crucial role in implementing all the requirements in the development process.
Highly flexible modules
The stations are integrated into a stainless-steel frame, conforming to a standard sometimes mandatory in food processing facilities. With the updated frame design, cable guides can be neatly laid throughout the machine. This is useful when extending individual modules to perform a new packaging activity. In addition, well-organised cable routes are also beneficial for future maintenance tasks or hygiene inspections. The product feed also differs significantly from the preceding series. “We believe that product diversity will continue to require significant flexibility regarding grouping functions. Because of this, we shifted the concept to a separate frame design so we can flexibly position and alter the required grouping and orientation features in this specific module without meddling with the packaging modules,” explains Bliemel. The machine also provides a modular approach to the product feed, making it ideal for the new SOMIC CORAS collection and sorting system. But more on that later.
Elevating the tried-and-tested to a new level
Making the machine even more user-friendly was a critical component of the development process. Quickly changing format parts and switching to a different product was already a breeze in the previous series. SOMIC has now surpassed these existing fast processes yet again: Most format changes are now managed by servomotors, meaning operators and their rapid changeover skills are no longer necessary. Time savings of up to 70% are possible when using the SOMIC QuickChange system to adjust folding tools, gluing positions, and blank magazines and for the subsequent changing of format parts. The implications of this for tight manufacturing schedules are easy to see.
The more frequently products are changed, the more clearly this benefit can be translated into efficiency gains. Relocating the automatic-filling gluing unit to the service cabinet is another user-friendly bonus. The SOMIC 434 has had some other minor design improvements to make it even easier to use: The support structure of the frame that holds the functional groups has been moved to the inside. This is much more than just a ’simple design improvement’. It allows the operator unrestricted access to the machine’s interior so the functional groups can be accessed simply by walking into the machine. In addition, the large machine guard doors open a full 180 degrees, maximising the available space around the machine. Highly visible LED lights on the corner columns indicate the machine’s operational state from a distance.
CORAS collection and sorting system
When designing its new collection and orientation system, SOMIC set out to provide unparalleled flexibility. How can collection, sorting, and product alignment be accomplished with maximum flexibility? Users frequently raise these questions during discussions. SOMIC has the solution with the introduction of the SOMIC CORAS collection and sorting system at this year’s Interpack.Breaking free from the customary processes, the team developed a planar technology-based drive and positioning system to create a compact and lightning-fast carrier solution for the unrestricted assembly of product groupings. “With this solution, we don’t need conventional sorting systems. Instead, we can use the planar system to sort things on the fly,” explains Mathias Wander, R&D director. The floating carriers can be programmed as required to put the products in any specified order. They can also rotate 360 degrees along the vertical axis.
With this innovative technology, SOMIC’s clients can complete their grouping and sorting tasks in roughly a quarter of the space required by the standard pick-and-place method. Furthermore, it can be expanded as required since adding additional modules is simple. SOMIC demonstrated this innovation at Interpack alongside the new SOMIC 434 docked onto the new machine platform. Using a space of around 2.5m square, the system processed tubular pouches containing nuts from four lines. The flexibility of SOMIC CORAS is one of its greatest strengths. Each track can load or unload about 30 carriers each minute.
A proven philosophy
Customer focus has been and continues to be the most essential driver of all SOMIC innovations. “We brought everything together when developing our new SOMIC 434: The wishes of our customers, which came out of many sales talks, future market prospects, findings, and the optimisation potential from the point of view of our developers, assemblers, and commissioning engineers,” emphasised Ralf Jäckel, who supported the development of the new machine as sales Europe director.
“Using the same tried-and-true features, we were able to create an entirely new machine concept in two and a half years of development work. The 434 is our response to future market trends.” And, of course, the director of sales is also particularly concerned with: “We are in a leading position in terms of energy efficiency. There have been no changes at all, and we continue to offer our clients the best possible service in this respect.” Managing director, Patrick Bonetsmüller, is delighted with the outcome of the presentation at Interpack: “The technical divisions have done a fantastic job of putting the shareholders’ strategic goal into action. Our development team was tasked with creating a new generation of machines to help us better fulfil our customers’ needs and set up our operations in a way that is both efficient and sustainable for the future. The result is remarkable. The development of this innovative machine concept took just two years. An incredible team achievement.”
