Drive and Automate Packaging Machines Safely

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Packaging machines must combine top performance, compact design, and sustainability. Lenze provides the right drive and automation solutions for this—from sensorless motors to non-stop robotics.

The demands on packaging machines are increasing: regulations for plastic reduction, the desire for more compact systems, and the requirement for maximum throughput call for innovative concepts. The drive and automation specialist Lenze provides tailored solutions that combine performance, flexibility, and sustainability in machine architecture. Below, we present four current solution approaches.

Precise Motion Control for High-Speed Tray Formers

The EU Packaging Regulation (PPWR) forces the industry to switch to alternative materials such as cardboard. For designers, this often means having to adapt existing line layouts. Lenze's drive and automation technology demonstrates that this is possible without compromising product throughput using the example of the high-performance tray former from its partner Mpac.

Through precise axis synchronization and accurate motion control, the system enables an innovative rotary feeding concept. This replaces traditional, intermittent ram systems and ensures stable continuous operation. The result is a compact system that forms and erects up to 200 carton trays per minute from flat blanks in a small footprint. Designers can thus realize PPWR-compliant solutions with constant cycle rates and high process reliability—all with optimal space efficiency.

When it comes to designing more compact, cost-effective, and material-efficient machines, engineers do not always have to rely on traditional servo technology.

Servo-Like Performance Without a Servo

When it comes to designing machines to be more compact, cost-effective, and material-efficient, developers don't always have to rely on classic servo technology. Lenze proves this with the Motor Drive System IE5/IE6, consisting of the i650 motec frequency inverter and the m550/m650 synchronous motor.

The system uses a sensorless open-loop control that delivers a starting torque of up to 300 percent at 0 rpm—entirely without motor feedback (encoder). For designers, the elimination of feedback systems and complex wiring translates to significantly reduced initial costs, less installation space, and simplified assembly. With an integrated logic PLC, positioning function, and integrated safety features (such as STO), the highly efficient system (up to 60 percent less motor losses) is ideal for conveyor drives, lifting applications, and positioning axes.

Compact Machine Design Through Intelligent Servo Inverters

In highly dynamic applications in packaging technology, developers face the challenge of limited space in factory halls and the demand for complex, synchronous movements. Lenze solves this problem with the servo controllers of the i950 and i750 cabinet series.

The i950 shifts motion intelligence directly into the drive. Using prepared technology applications (such as electronic cam profiles), complex movements can be represented electronically. This replaces elaborate mechanical motion guides, saves significant space, and reduces machine wear. For multi-axis applications with extreme synchronization requirements, the i750 cabinet, in combination with the One-Cable Technology, offers the highest repeatability. The open architecture of the controllers enables designers to quickly create modular machine designs for maximum throughput per square meter.

Inline Robotics Maximizes Throughput

Every machine downtime costs valuable time. Cycle interruptions during pick-and-place operations can be completely avoided with Lenze's inline robotics using the so-called "rotary tracking".

Instead of operating on a stop-and-go principle, the robotic kinematics (e.g., a delta robot) computationally follows the continuous motion of the mechanics (such as a rotating table). Servos and encoders capture the axis positions in real time, after which the Lenze controller calculates a dynamic target path—the robot picks up and places the product during ongoing operation. Designers benefit from the Lenze Fast Application Software: robotics is not programmed extensively but rather parameterized according to PLCopen standards. Since motion, logic, and robotics run on a common platform without additional robot control, system complexity is drastically reduced. A digital twin also enables virtual pre-commissioning, which significantly shortens the time-to-market for the packaging machine.