Role of simulation in predicting the effect of machine settings on process performance in the packaging industry

Recent European Union regulations on packaging waste have resulted in a trend towards light-weighting and greater use of recycled materials in the packaging of consumer goods. This has impacted particularly upon the folding carton industry, and has necessitated greater fundamental understanding of the machine-material interactions that take place during carton production. One way to achieve this is through the use of simulation models. Such a model has been created to simulate the behaviour of a folding carton during the critical transition between flattened and erected states. The model is able to simulate process failure (buckling) and investigate the effect of changes in pack, process, material, and tooling parameters. The model is applied here to investigate the effect of variation in two key machine settings. These are the relative orientation of tooling, and the contact points between tooling and carton. The results of the simulation reveal a strong correlation between theoretical and practical results, and as a consequence provide a means for determining the optimum tooling position(s). The study demonstrates the ability of simulation to support the set-up and operation of complex packaging machinery. It is arguable that such tools will be essential for machinery and consumer goods manufacturers to compete in today's highly competitive global markets where quality, efficiency, and flexibility are critical.