Rockwell around the clock

Rockwell Automation has been active in the area of robotics for many years, applying its Integrated Architecture control systems and partnering with robotics manufacturers. Packaging Today caught up with François Bonny, OEM Business Development Manager Packaging EMEA to find out his predictions.

Packaging Today: In order of importance, which factors are particularly stimulating the assimilation of robotic packaging solutions at the present time?

François Bonny: The main driver is flexibility. In the past, manufacturers needed to set up, maintain and operate dedicated production lines, which was inefficient on numerous levels. Now, it is only necessary for the operator to input the size and weight of product, together with the packaging type. The second major factor is economics. Obviously robots replace operatives and the systems operate at higher speeds, realising packages in a precise, uniform manner. However, the practicable speeds are determined by product type and the favoured packaging style.

Packaging Today: In which aspects of the packaging industry are they are particularly being used?

François Bonny: I would just like to clarify that Rockwell specialises in automation systems for food applications, particularly in relation to the pick ‘n’ place robots used to package biscuits, chocolate, cheese and convenience foods. It also supplies systems for top-loaders, which are used for secondary packaging.

There has been an explosion in the assimilation of robotic solutions during the past decade, but this has particularly hit home during the past two years as several important patents have expired. This has opened up the market, increasing competition and driving prices down. Furthermore, prior to patent expiry, it was often necessary to purchase an entire line that incorporated a robot just to achieve the robotic solution. It is now possible and more often the case that the manufacturer invests in a robot and retrofits it to a line, thereby considerably reducing the entrance costs of incorporating robotics.

Packaging Today: What role does Rockwell Automation play in the development of technologies that improve the efficiency of robotic concepts? How does it partner with robot manufacturers?

François Bonny: We work in two main ways with our OEM customers. Rockwell provides standard PLCs for the control of the OEM’s robots and communications with the remainder of the line. This is more efficient and cost-effective, particularly from the maintenance perspective. Only one software package, RSLogix 5000, is required for the complete line, cell and robot control, programming, commissioning and maintenance. Our controller can integrate with most of the vision systems on the market. All this serves to reduce the requirement for inputting and calibration, the purpose of which is to reduce errors. OEMs can also customise their system by using our add-on instructions.

We also partner with machinery builders who specialise in robot designs in Europe through our Dutch partner PWR Pack and via AFAST Robotics in the USA.

Packaging Today: Rockwell has recently undertaken a programme of investments, most noticeably at its OEM Competency Centre in Hamburg. What were the reasons behind this?

François Bonny: We already had two competency centres – one in the UK and one in Bologna, Italy. The latter is for southern European customers and we needed to expand the UK centre to cover northern Europe, but this was impossible at the UK site. Hamburg was considered suitable because it is located near many machinery builders in such areas as Scandinavia, the UK, Northern Germany and The Netherlands. The centre now incorporates the three main robotic types: pick ‘n’ place, SCARA and linear robots.

Packaging Today: Does Rockwell consider that robotic solutions developed in the Far East present a real threat to its core business? If so, how is it combating this?

François Bonny: We don’t really consider this to be a threat. There is a strong history of machinery construction in Europe and there is always a timelag before manufacturers in emerging economies try to replicate the latest technologies. The core innovations always come from Europe and we follow and partner the European machinery manufacturers.

Packaging Today: Which technological developments are making robotic solutions suitable for use by a deskilled workforce?

François Bonny: When production modifications are being made, skilled people are needed to accurate input the data and recalibrate the line, including the robot. However, hardly any operatives are required during operation and PLC interfaces do not require specialist knowledge for operation.

Packaging Today: Will the onset of recession have a positive or negative impact on the uptake of robotic solutions?

François Bonny: This will have a positive effect. Manufacturers need to automate production even further to reduce costs. We are actually noticing an increasing trend towards the use of robots for non-food applications.

Packaging Today: Do you see robotics being introduced outside of the Western European and North American markets, where labour has traditionally been cheaper?

François Bonny: Yes, we do. Our OEM partners are receiving increased levels of orders for robotics from the Far East and Russia, amongst others. The drivers are not just reduced labour costs – to compete internationally, manufacturers need to efficiently package products in a consistent manner.