Optimizing packing plants for perfect flow
Haver & Boecker leverage packing process expertise to offer customers several unique diagnostics options
HAVER & Boecker leverage their expertise in the full packing process to provide customers with unique diagnostics tools to optimize packing plants with their QUAT2RO System Intelligence, the Plant Optimization Plan (POP) and the Bag Optimization Plan (BOP).
Comprising the diagnostics section of Haver & Boecker’s PROcheck lifecycle approach, these systems: help operations increase plant performance; optimize machine conditions, set up and use; raise health and safety standards; and improve energy efficiency.
‘We designed the PROcheck approach to maximize productivity and results over the entire lifecycle of a packing plant. As the first part of the circle, our diagnostics tools often lay the foundation for future efficiency improvements. People come to us with their packing issues and we provide answers to those challenges,’ said Andreas Hansow, service support for Haver & Boecker. ‘We then offer options to optimize the entire plant and achieve each operations’ perfect flow.’
QUAT2RO monitoring tracks packing line performance in real time to document performance, observe process efficiency, and note data in a digital logbook. The results are used to check production and identify solutions to productivity challenges and inefficiencies.
A Plant Optimization Plan (POP) is another diagnostics tool that provides a detailed report to customers with a current operation overview, areas of improvement, and updated recommendations for their packing process classified by level of urgency.
To start, a system specialist inspects the plant in an on-site audit. The full plant audit considers all areas from product storage and handling to packing, bag transport, palletizing and loading lines, as well as surrounding machines and environmental factors in the plant, resulting in a thorough, in-depth report with detailed findings.
Each recommendation in the report is coded with a red, yellow, or green tagging system to show the severity of the issues being faced. The system specialist explains the results of the POP before providing customers with the final report in a digital file. With input from plant and maintenance managers, the Haver & Boecker team completes the suggested improvements to the packing line.
A Bag Optimization Plan (BOP) provides operations with insight into how the bag performs with the customers’ machine and product. The process includes a bag volume test, bag valve check, visual pallet check, and a bag specification check. The customer can choose to send their current and/or desired bags to the Haver & Boecker Institute to complete a BOP. The experts analyse the bag before presenting a report detailing recommendations for any bag or related equipment improvements.
When combined, a POP and BOP ensure all three major factors in the packing process – machine, bag and product – are working in harmony, resulting in the highest levels of productivity and efficiency.
‘The PROcheck lifecycle approach extends beyond an evaluation to consultations on equipment, upgrades, and diagnostics over the lifetime of the plant,’ said Engelbert Köß, general manager of Haver & Boecker Service. ‘Like every good doctor knows, the key to good health is not just treating symptoms but finding the root cause. A packing plant works the same way. Our experts provide smart services, software, and analytical components to monitor plant health and ensure you can reach the perfect flow, because only healthy processes are truly economical.’
