Changeparts- Zepf Technologies UK

The packaging line is complete. The layout of machines and configuration of the conveyor systems and operational controls has been determined to provide maximum performance.

All the detection and reject systems are in place; the modelled exercise indicates that the line will run at an efficiency of 90% plus. In practice in didn't happen like that? Forgot about the people and material interface to the machines? Start again - the packaging line exists - what do we know about it? Main thing is that if we set it up and have long production runs on the same product we get better efficiencies - except that one particular container size always gives us lots of problems?

How good is your company at carrying out changeovers? Do you measure the cost of every size/product change on your packaging lines? Does everyone know his or her role in the changeover process? Are changeover instructions and checklists in place?

Having thought about all the operational issues eventually we come to the parts, the actual parts that handle the containers, the parts that position and control the container through the machines, through the processes that determine finished product quality. The finished product that the customer purchases! Surprise, you need a long-term strategy for the purchase of container handling changeparts - does your company have one?

Your strategy should be based on the principles of ensuring consistent reliable processes across all packaging lines. Perhaps working with one preferred reliable supplier is the best method of achieving this; bearing in mind OEMs are normally only capable of supplying parts for their own equipment. You need a reliable, capable changepart supplier.

Just how important are container-handling changeparts?
Is one supplier better than another?
Do the changeparts impact performance?

Are the parts:

• Designed to maximise efficiency?
  
• Easy to remove to carry out size changes and cleaning?
  
• Lightweight to support manual handling regulations?
  
• Easily identifiable?
  
• Designed to eliminate the use of tools?

The answers to the above general questions are very much dependant upon the answers the customer gives to the following typical questions:

• Do you need reliable manufacturing processes?
  
• Is producing a quality-finished product important to you?
  
• Do you care about your employees' well being?
  
• Do you have frequent changeovers?
  
• Is there a constant demand for more flexible production processes?
  
• Would you like quick reliable changeovers and minimum ramp up time?
  
• Would you like to free up the time of your more skilled engineering labour?
  
• Do you want continuous improvement to be the norm?

And many more…………

Changeparts

The key to achieving all the possible benefits relating to changeovers lies in the quality of the changepart design staffs' skills, knowledge and experience of packaging equipment and the capability of the design software package. Most container handling changeparts consist of a combination of stainless steel and plastic materials that are normally sufficient for purpose. One of the means that Zepf Technologies UK use to differentiate our products is that we use only the best quality materials within reasonable cost. Our range of 14 colours and the use of 1000 grade virgin UHMW polyethylene is unique within the industry. Most other companies use the less expensive 500 grade and offer only 1 - 3 choices of colour. The wear resistant properties of the 1000 grade material are far superior to that of the lower 500 grade and not just by a factor of two.

The Zepf UK business is totally focussed on the design and manufacture of container handling parts and associated products. Our main product is the CORE and RACOP (RApidChange OverParts) quick changeover system where the core component becomes a permanent fixture on the machine and each container size has its own coloured set of racop. Zepf UK changepart design capability is second to none in the packaging industry as we employ 10 highly skilled dedicated changepart design engineers and use the most advanced customised 3D modelling software available on the market. One of the main benefits to our customers is that our investment in the new generation 3D software enables our designers to create virtual reality visualisation of the finished product. Modern technology allows us to E-mail drawings of the finished product to customers around the globe that look like colour pictures or even better an animated colour film in the form of AVI files. This can be particularly useful to demonstrate the arrangement of parts in complicated assemblies by exploding views and providing virtual reality motion on a computer screen. Another benefit of using 3D modelling software is the built in clash detection which supports ‘ right first time ‘ supply to customers. A responsive high level of service is the norm when working with Zepf UK as many customers all over the world can verify.

It is no accident that Zepf UK's impressive customer list includes many blue chip business sector leaders. Generally these are the companies who have the vision to recognise that their employees are their greatest assets and that market forces are more and more demanding flexible production capabilities. Investment in Zepf UK style quick release, no adjustment, lightweight, colour-coded changeparts fully supports that kind of strategy. At the present time there is ample opportunity for smaller businesses to benchmark these leading companies and use the Zepf UK knowledge base to gain competitive advantage by adopting an appropriate long-term changepart strategy.

New Product / Container Development

As more and more customers become aware of our new generation design capability they frequently ask us to participate in actual container design meetings in their premises. The ability to import container manufacturer drawings in DXF, IGES or STEP file format enables design time to be reduced dramatically and customers can use this capability to foresee and discuss issues even before a container mould has been produced. It also allows the customer to discuss technical issues with marketing personnel armed with accurate information that was previously not available. AVI files can be created and these can even provide an animated film of containers running through machines. Maybe the future is that the technical people will tell marketing departments what shapes and features a container should have, I somehow doubt it! Perhaps the answer lies mid way? In any case Zepf UK can support fast-track container handling solutions for all customers.

Conveyor Guiderails

Again Zepf Technologies UK design capability enables us to generate innovative solutions when dealing with 'difficult to handle' containers. Many customers have benefited from this design expertise and frequently they have come to Zepf UK on the recommendation of other satisfied customers who have experienced massive production gains from our solutions. Although our main area of expertise is container handling for rotary packaging machines the expertise we have gained over many years can often be used to develop quick-change solutions for other applications.

By using the same principles as applied to our quick release container handling changepart system i.e. core component and removable rapid changeover part we have designed many bespoke systems to the delight of our customers who have often suffered specific problems for many years. This is very pertinent when solving problems relating to traditional single-track conveyor bends. We have many examples of successful solutions in this area and even more recently we have demonstrated successful solutions for multi-lane conveyor systems using quick-change core component and rapid change part design.

Normally Zepf UK guide rail systems adjust to fixed points or have no adjustment whatsoever, resulting in optimum reliability. Some designs incorporate the use of colour coded spacers or alternatively has both horizontal and vertical adjustment built in. Our experienced designers determine the optimum solution for customers' particular problem after visiting the customers' site.

Feedscrews

Zepf UK again uses a unique piece of customised software to design superior feedscrews to those of our competitors. Our unique software enables us to design the best feedscrews in the packaging industry and gives us a distinct competitive advantage in the production of feedscrews to handle difficult and complex shaped containers. The software calculates the movement of the containers in 1-degree rotations giving optimum design accuracy for the pocket shape of a feedscrew.

The design of our feedscrew quick release system enables the simple removal and replacement of feedscrews without the use of tools and eliminates the need for timing between size changes. We use the identical UHMW polyethylene material and have the same colour range to that of our changeparts. The construction of the assembly results in feedscrews that are generally the most lightweight available.

Possible feed screw container applications:

• Accelerate
  
• Decelerate
  
• Pitch
  
• Turn 90 degrees
  
• Orientate in one chosen direction
  
• Group together
  
• Combine 2 lanes into one
  
• Change 1 lane to 2 lanes
  
• Transfer product

Other Products

Other changepart products of Zepf UK include, quick release bottle platforms, labeller wipe stars, quick release pedestals for cleaning and filling machines, gripper stars, labeller spotting stars and centre guides, anti-rotation stars and guides for capping turrets, product protection covers, changepart trolleys.

Other products and services include machine safety guarding and electrical upgrades to PUWER regulations and general process improvement and container orientator equipment.

Conclusion

In summary, if your company wishes to gain competitive advantage and pursue a long-term strategy for the purchase of container handling parts then you should form a partnership with a reliable supplier. To secure maximum benefit that supplier must be capable of implementing solutions through innovative design. The supplier will then be naturally capable of transferring knowledge gained from experience to the benefit of your organisation and will be able to support SMED activity and continuous improvement throughout your production facility.