HFFS Application SolutionsHorizontal Form Fill & Seal MachineHorizontal Flow Wrap Line

Helping You To Design, Develop and Deliver

• Faster time to build HFFS Line.• Object oriented combined with common network based architecture to

support modular design.• Modular program concepts to reuse of code.• Optimized mechanical components with increased line performance.

Machine Basics & Challenges • Wrapper film feeding in-line to product length.• Product feeding into wrapper zone and matching the print mark to align with product length.• Rotary knife or cross sealer to synchronize with wrapper linear speed and cut length.• Adjust machine speed without stopping running machine - On fly machine change.• Empty wrapper out leads to wastage.

Pre-tested & Validated Instructions • Advance registration control with length compensation and position correction of laminate.• Advance CAM design with controlled jerk for rotary knife and film movement.• Advanced smart belt control algorithm for smooth product flow in to wrapper.• Sample code to support `No Product No Bag` feature.

Benefits of Rockwell Solutions • Reduction of lamination wastage due to “No Product No Bag” feature.• Improved OEE of line due to auto-recovery of most common production errors or faults.• Improved productivity of machine parts as they operate with controlled jerks with reduced vibration.• Support of machine code & operator interface in-line to global standards (PackML, ISA 88 Etc).

HFFS - Intermittent or Continuous Machines Typical Architecture for Customized Machines

• Advanced Human Machine interface with ability to set machine variabilities such as wrapper length, laminate slip factor, sealing time, adaptable speeds to match upstream and so forth.

• Advance Motion control enables machine to improve with more flexibility.

• Servo motors with food grade and wash down environment, exclusively required in Food and Life Science Industries.

Packaging Speed Up to 250 Packs per Min.

Network EtherNet/IP™

Controller CompactLogix™ L2

Variable PowerFlex® 523Frequency Drive

Servo Drive Kinetix® 5500

Synchronous Motion Up to Four Axes

CompactLogix L3Controller

Studio 5000 Logix Designer™power programming which allows program designs to be modular for easier programming and higher equipment safety. It saves significant engineering time, enables faster startup, and commissioning.

Optimized electronic CAM profilesmotion control systems may ensure smoother machine operation and enhance machine mechanical life.

Optimal machine speeds by using motion sizing tools - Motion Analyzer.

Diagnostic information regarding Servos available on Human Machine Interface.

Programmable for constant seal-time for any machine speed.

Dynamic change of machine speed and corresponding sections synchronize with Controller Master reference.

Application program based on Pack ML State Model.

Studio 5000Logix Designer

Stratix Switch EtherNet/IP

Kinetix 5500 Servo Drives

Compact Logix L2 Controller

PanelView PlusHuman Machine Interface

Film Feed

In Line Pusher 1

In Line Pusher 2

PowerFlex Drive

Cross Pusher 1

Cross Pusher 2

Packaging Speed Up to 600 Packs per Min.

Network EtherNet/IP™

Controller CompactLogix™ L3

Variable PowerFlex® 525Frequency Drive

Servo Drive Kinetix® 5500

Synchronous Motion Up to Sixteen Axes

Typical Architectures Various Range of HFFS Machines

Scalable Architectureswith common controlsystem environmentto address low speedmachines to highperformance linesby connecting overUpstream Equipmentto Downstreampackaging lines.

Scalable control with a single programming environmentwith integrated motion instructions.

Higher capability and scalabilitywith up to 30 I/O modules and 16 motion axes.

Integrated recipe managementrecipe controls allow companies to sidestep the repetitive process of tuning machines during a line change by saving and managing multiple settings.

Common Human Interfaceplatform and networking services.

Built-in security capabilitiessupport security standards, particularly ISA SP99. Collaborate with IT security specialist company such as CISCO to leverage on their expertise.

Safety enabled throughout.

HighPerformance

Lines

CompactLogix L3with Kinetix 350 or Kinetix 5500 & AC Drives

CompactLogix L2System with EtherNet/IP

Low SpeedSolution

Studio 5000Logix Designer

Stratix Switch EtherNet/IP

Kinetix 5500 Servo Drives

Compact logix L3 Controller

PanelView PlusHuman Machine Interface

Smart Belt Conveyor -1

Smart Belt Conveyor -2

Film Feed Drive

In Feed Belt / Lug Chain Conveyor

Rotary / Cross Sealer -1

Rotary / Cross Sealer -2

PowerFlex Drive

Film Feed

ControlLogix L6 All Servo System

2

3

4

5

1

1783

-US5

T

PWR

2080-LC50-24QBB

MAC ID00:00:BC:CE:3A:10

RUN-REM-PRG

Micro850™

MS NS

COMO • I-00 • I-01 • I-02 • I-03 • I-04 • I-05 • I-06 • I-07 COM1 • I-08 • I-09 • I-02 • I-10 • I-11 • I-12 • I-13

COM • 0-00 CM1 • 0-01 CM2 • 0-02 • 0-03 • 0-04 • 0-05 CM3 • 0-06 • 0-07 • 0-08 • 0-09+DC • -DC 24 24

Intermittent Machine - Typical Architecture for Entry Level

Connected Components - proven optimal configuration. Cost effective solutions. Reduced panel engineering enables a shorter time for wiring and thus improves machine assembly time. Availability of plug-in modules at the controller allow for expanded machine features and functions.

Common Programming SoftwareConnected Components Workbench for Micro800®, PowerFlex® (AC Drives), PanelView™ Components.

Advanced Motion Controlsupports up to three motion axes using ‘Pulse Train Output’.

Versatility of Interfaces up to six high speed counter inputs and up to three ‘Pulse Train Output’ over embedded digital I/O. Up to five plug-ins and up to four expansion I/O modules.

High Flexibility plug-in and expansion modules allow you tooptimize your machine cost bychoosing performance and functionality specific to your machine needs.

Touch Probe Function able to capture accurate registration position at high speeds with built-in hardware. Packaging Speed <80 Packs Per Min.

Network MODBUS RTU, Ethernet/IPController Micro800 FamilyVariable PowerFlex® 523Frequency DriveServo Drive Kinetix ® 3 and 300Motion Up to Three Axes

Connected Components Workbench Software

Micro850® ControllerShafted Machine Master Encoder

Film Pull Belt

FilmRegistrationSensor

Cross Jaw

Kinetix ComponentClass Servo Drive

PowerFlex Drive

Kinetix ComponentClass Servo Drive

Film Unwind

Infeed Conveyor

PowerFlex Drive

PTO

Stratix™ Switch

PanelView™ 800Human Machine Interface

MODBUS RTU

Supporting Your Business Every Step of the WayAt every stage in the life cycle of your machines, Rockwell Automation is your collaborator. From design to build to operation and maintenance, you can count on the continuum of Rockwell Automation resources.

By taking advantage of our products and services, you can lower your total cost to design, develop, and deliver, while improving your time to market. You will be better equipped to react quickly to change, increasing profits and attracting new customers with

high performance and innovative machines. Whether providing you with single components, entire systems or specialized consultation or trying to achieve sustainable production initiatives, our goal is to offer solutions on a personalized level.

For More Information:Call a Rockwell Automation sales office or an authorized distributor today or visit us online at www.rockwellautomation.com

OEM-BR047B-EN-P (AP with map) OEM-BR057B-EN-P (Global without map)Publication OEM-BR057B-EN-P – July 2015 Copyright ©2015 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Allen-Bradley, Connected Components Workbench, Compact Logix, Kinetix, LISTEN. THINK. SOLVE., Micro800, Micro850, PanelView, PowerFlex , Rockwell Automation, Rockwell Software, Stratix, Studio5000 Logix Designer, and Total Cost to Design, Develop and Deliver are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVA. All other trademarks and registered trademarks are property of their respective companies.

For more information about our OEM Solutions, please visit: http://www.rockwellautomation.com/go/lit/oem

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