The packaging industry has to take action if it wants to meet the increasing customer requirements in the field of fast moving consumer goods (FMCG). High-performance machines that incorporate modern automation components are an important lever for greater speed and flexibility in this dynamic industry. WOLF Verpackungsmaschinen GmbH has taken its vertical form, fill and seal machines to a new level with solutions from Bosch Rexroth’s automation system ctrlX AUTOMATION – and also benefits from a fast time to market thanks to the simple implementation and the supplier’s strong delivery performance.
WOLF Verpackungsmaschinen GmbH manufactures vertical form, fill and seal machines. More than 4,000 machines installed worldwide offer companies solutions for the efficient packaging of products weighing from 5 g to 10 kg. The machines package a wide range of products – from food, such as chips, to chemical and pharmaceutical products. WOLF’s customers are predominantly medium and large producers from the FMCG sector.
“Our orders often have a rigid timeline, as the machines are usually integrated into the lines only in short time slots. During the coronavirus pandemic, there were significant bottlenecks in the availability of standard components. This led us to search for a new supplier, which on the one hand can ensure very high delivery capability, also independently of global supply chain problems, and on the other hand offers us the key to the future viability of our machinery. Bosch Rexroth had the answer to both of these,” says Arno Wördemann, Sales at WOLF Verpackungsmaschinen GmbH.
Tobias Gerhard, Senior Business Development Manager Consumer Goods at Bosch Rexroth, explains what is important in automation today: “Packaging machines have to do more and more, and above all become more efficient, but also adaptable. Increasing customizability means more effort and expense. However, ever higher productivity is needed at the same time. The key to responding to these requirements is flexible, scalable automation. The automation system ctrlX AUTOMATION is designed to enable the necessary agility in this highly dynamic industry.”
ctrlX AUTOMATION includes all the components required for complete automation solutions – from controls, I/Os, IPCs and HMIs to the most extensive software functions, as well as motion and drives. The partner network ctrlX World is continuously expanding the solution space with hardware and, in particular, apps. The foundation is the Linux-based operating system ctrlX OS with ecosystem – an open world of automation. This offers end users a comprehensive range of modular and scalable solutions for a wide range of use cases.
Today, WOLF uses the industrial control system ctrlX CORE with integrated motion control (ctrlX MOTION), the compact servo drives ctrlX DRIVE, the ctrlX I/O modules with interface diversity for communication and the safety solution ctrlX SAFETY. All components were seamlessly integrated into the existing infrastructure at WOLF.
Arno Wördemann says: “The solution was implemented during ongoing operation and took about three weeks. We deliberately planned a larger buffer due to the complexity of the changeover. Both mechanical and programming requirements had to be met for successful implementation. The solution had to be fully compatible with our standard code and ensure smooth integration into our existing mechanical systems. All of this worked brilliantly.”
The modernization of the vertical form, fill and seal machines brings crucial benefits for WOLF. The compact size is a big plus. The size of the servo drives ctrlX DRIVE is significantly smaller than the standard solution used to date.
Arno Wördemann explains: “The compact size of the ctrlX DRIVE significantly reduces the required control cabinet space, while the MS2N servo motor’s single-cable connecting technology minimizes the cabling. In addition, the web-based and Wizard-supported engineering with integrated motion control of ctrlX CORE has been designed to be incredibly simple. ctrlX MOTION is easy and intuitive to program. Bosch Rexroth provided uncomplicated engineering support and enabled us to implement the machine within the shortest possible time.”
WOLF therefore benefits from a fast time to market. Bosch Rexroth’s delivery performance also contributes to this. The high availability of the components ensures continuous manufacturing capability. An essential requirement, not just in times of supply bottlenecks. “Finding Bosch Rexroth as a partner is a blessing for us. This has enabled us to secure a very important order that would probably not have been feasible otherwise,” says Arno Wördemann.
Bosch Rexroth also offers WOLF a comprehensive range of services. The quick and competent support made the installation of the new solution much easier and helped ensure smooth implementation. The service provided by Bosch Rexroth ranges from support during the planning phase to successful implementation and beyond.
WOLF has laid the foundation for future-proof manufacturing – in two respects. On the one hand, the Linux-based operating system ctrlX OS and control platform ctrlX CORE are secure by design and secure by default and thus perfectly prepared for the requirements of the Cyber Resilience Act (CRA) – indispensable in the age of digitalization. On the other hand, the manufacturer can now offer packaging machines that enable its customers to meet the requirements of customization, speed and flexibility in the FMCG industry. This gives WOLF a real competitive advantage as a medium-sized company. Extensions to the automation solution are already in the planning stage.
If you have any questions or require further information regarding ctrlX AUTOMATION, please contact us:
Arno Wördemann
Sales
WOLF Verpackungsmaschinen GmbH
„Openness is everything“ – this is the motto of the ctrlX AUTOMATION magazine 2023/2024. This year, it´s all about openness and co-creation, which enables a completely new world of automation. Furthermore, there will be innovations of the product portfolio, exciting case studies and expert opinions on digitalization and connectivity.
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