LSS Gives You Total Control
On a production line, every second counts. Any disturbance, like a bottleneck or a jam can cause a reduction in Overall Equipment Effectiveness, resulting in lost time, and lost revenue.
It may sound cliché, but in production lines, time is money, and it was for this reason Infinity developed Line Synchronization and Simulation software.
Infinity’s LSS, gives operators the ability to control the speed of the line and harmonize the downstream system as a single unit.
LSS is able to accomplish this by monitoring downstream machine process data, the accumulator level and the line’s target speed. LSS sets the target speed for the line, based on individual bottlenecks, and then controls speeds for all the equipment.
This is essential in tissue converting lines as they need the ability to feed enough product for wrappers to continuously run, while the downstream equipment needs to be able to run faster than target speed when there is a backlog.
The LSS software continuously monitors downstream machine process data including the machine speed and material status. Then LSS adjusts the line to compensate for any changes that arise. These adjustments could be anything from increasing the speed of a leg, to letting an accumulator fill to a certain level or even slowing down the line to clear a disturbance.
The data used by LSS is controlled by the master programmable logic controller which can be shared with another machine PLC or a dedicated PLC.
Identifying bottlenecks, and altering line speed in accordance with upsets ensures that machines are operating at their maximum uptime and least mechanical stress. By reacting to line irregularities, LSS can resume full production quickly, resulting in increased OEE.
However, Infinity LSS doesn’t just react to changing circumstances, it also anticipates them. LSS can account for changes in raw materials on a machine, the speed of the machine can be increased to create a time buffer for the change in material.
In addition to this, LSS can also anticipate disruptions by monitoring for a presence or absence of products in a certain area. If there is an irregularity in the flow of a product, we can pause the line for a conveyor jam.
Since different products and different configurations can change the target speed, requirements, or overall objectives of a line, LSS is completely customized based on a consumer’s unique requirements. Features like output path adjustments, accumulator level monitoring and log distribution can all be tailored for a consumer.
Another key component of Infinity’s LSS is the simulation service. By using Emulate 3D software, Infinity emulation engineers can create a functional three-dimensional virtual version of the product line. This allows customers to see their line in action, test different product formats, check photo-eye positions, speeds and production data, all before installation.
In essence, our LSS program allows our customers to have confidence in their purchase by giving them a virtual check-out.
The LSS service also offers customized Human Machine Interfaces that display the entire packaging system. The LSS HMI gives the operator a visual of the states/faults of the conveyor section, and also allows them to change drive section controls from automatic to local.
From the top down, Infinity LSS was designed with efficiency in mind. This unique service allows for maximum OEE, pre installation testing and personalized, user-friendly HMI. To learn more about our LSS services, reach out to your nearest Infinity Sales office.
Monalisa invests in full packaging line from Infinity.
Infinity Machine and Engineering Corp., a world-wide leader in packaging machinery for the tissue industry, will supply Monalisa, located in Nonsan-si, South Korea, a full packaging line. The line will be installed by June of 2021.
Infinity is supplying all the equipment on the packaging line between the log saw and the palletizer. The packaging line includes one (1) Eclipse T4 wrapper, one (1) EPXL bundler, one (1) ItaPack handle applicator (integrated by Infinity) and the conveyor system. Monalisa chose Infinity for this project because they required a system that was flexible for their changing market and they desired robust equipment that will last the next 20+ years. All equipment being provided is built with Infinity’s notable machinery characteristics like rugged steel frames, oversized bearings and overall top-of-the-line componentry. In addition, all machinery uses a SIEMENS processor.
The Eclipse T4 wrapper on this line will be able to run everything from single roll bath tissue to larger bath tissue pack options like 30-packs and 48-packs. The Eclipse T4 wrapper has become a tissue industry staple during the last four years with over 100 wrappers now in production throughout the world.
Not only will the Eclipse T4 wrapper provide more packaging options but so will the bundler on this line. The bundler is called the EPXL. It has a wide product range and can make small and large bundles. The EPXL bundler has a continuous motion design with linear servo movement of the knife and seal jaw. This allows Monalisa to fulfill their current bundle demands, but also gives them the ability to make bundles
with graphics applied to the poly. Since this bundler is continuous motion, it is able accurately follow registration marks and auto correct for misalignment. Other features of the bundler include an integrated diverter and flight bar system for easy product collation, automatic poly reel splice and poly pull out cart for safe poly loading.
Finally, the conveyor system on Monalisa’s line plays an important role in the creation of the product. The system is equipped with an Itapack Handle applicator and every turning, tipping and knock-down device. This allows Monalisa to apply handles to the packs in any orientation and position the packs into the bundle in any orientation as well.
Infinity’s line that has been delivered to Monalisa was designed, built and tested with extensive customer input throughout the COVID-19 pandemic. Monalisa was able to see weekly progress through Teams meetings and check the line out virtually. This project truly represents what Infinity stands for robust, flexible, custom and customer-focused tissue packaging solutions. The line will allow Monalisa to offer new packaging options to their customers and will give Monalisa the ability to do this for years to come.
Infinity Machine & Engineering Corp. Expands Engineering and Manufacturing Facilities
Due to tremendous growth, Infinity Machine & Engineering Corporation, a market leading manufacturer of tissue packaging equipment including wrappers, bundlers, casepackers, diverters, conveyors and case sealers, has broken ground on a new 8,900 square meter expansion (96,000 sq. ft). Currently, Infinity is split between four facilities, three of which are in Green Bay, WI USA and the fourth in Bologna, Italy.
The new expanded facility in Green Bay, USA will be a total 16,000 square meters (172,000 sq. ft), which along with its facility in Bologna, Italy of 1200 square meters (13,000 sq. ft), will perfectly position Infinity to continue to grow its business and serve Infinity customers world-wide.
The purpose of the new expansion is to allow Infinity to offer greater manufacturing capacity to customers, implement manufacturing process improvements, expand product line offerings, have a dedicated R&D area, expand its training facilities, and to allow for full packaging line set-ups.
Some new features of the building expansion include; a monorail trolley system for powder coated parts which will more than double the paint capacity, adding an additional six final assembly bays (currently there are 13), and also adding additional “pre-build” areas to speed up production. The new expansion will also offer an expanded machine shop, a state-of-the-art quality assurance lab to verify the accuracy of parts, and an additional 1,200 square meters specifically for conveyor production. The expanded manufacturing facility is designed with the intent of creating an efficient flow from parts manufacturing, painting, job staging, assembly, check-out, and machine shipment. Natural light throughout the shop also creates a bright and open environment.
In addition, Infinity is also expanding its engineering offices to allow for increased engineering capacity. The new office will allow Infinity to have a total engineering staff of almost 40 engineers. Currently Infinity employs around 30 engineers. Infinity will also have a space dedicated to packaging line synchronization and simulation which will feature a virtual reality studio and large monitors for simulated line inspections before the actual installation. Also, the customer service area will be expanded to allow for more remote troubleshooting facilities, machine monitoring, engineering collaboration, and increased capacity.
Between the years 2016 and 2019, Infinity has more than doubled in size in terms of machine shipments and revenue. The growth of Infinity, however, is not represented best by the amount in sales or the number of machines in the market, but by the people that make up the company and its valuable customer base. In 2016, Infinity had 85 employees and just four short years later, Infinity now employs over 170 people between engineering, purchasing, production, shipping and service. The expansion of the building will follow this growth and allow for Infinity to further serve the world market with robust, reliable and technologically advanced tissue packaging equipment.
Brick by brick, project by project, and idea by idea, Infinity’s intention is to grow without limits and to do our best to help our customers realize their maximum potential. In virtually every facet of the Infinity organization, Infinity strives to reach perfection and provide longevity and continuity for our customers, our employees, and our community. We manage our operations while focusing on three important principles: always give our best effort, work in concert with our values, and simply do what we say we will do.
