Industry 4.0 Ready

At TrakRap we understand that digital technology is transforming productivity in the food industry. Therefore, working closely with our technology partners, Siemens, we are continuously developing innovative solutions for our machines that will most benefit our customers.

The TrakRap machine is a fully automated digital system that is fully Industry 4.0 enabled.  Whether it’s preventative maintenance through remote monitoring via Mindsphere (The Internet of Things), MES auto set up, integration with upstream production, data to monitor shift patterns, up time performance and productivity, right down to simple manual feeding.  With a wide speed range from as little as 3 packs per minute right up to 50 packs per minute, the flexibility of the system is unparalleled.

Industry 4.0 Highlights

  • Total Cost of Ownership (TCO)

    Pay per use, no capex, only pay for what you use.

  • Flexibility

    Multiple pack sizes, formats, fast changeovers and one film fits all packs.

  • Overall Equipment Effectiveness

    Outstanding reliability and uptime performance.

  • Integration

    Siemens Totally Integrated Automation (TIA) and Profinet.

  • Smart Energy Consumption

    Cut energy use by up to 90% & use up to 70% less film.

  • Productivity

    Variable line speeds, 3 -50 packs per minute

  • Connectivity

    Sinamics integrated web server for efficient diagnostics and maintenance.

  • Simulation

    Virtual commissioning, digital twin, Human-robot collaboration.

By using a digital twin, it means that we can build an exact replica of the real-life machine and run it though different staging environments to prove that it can work in any combination of real-life operational situations, and it’s backed by a plan for assembly, implementation and installing your machine!

Our digital twin monitors and displays the machine’s performance throughout its entire lifecycle, allowing users to predict behaviours and implement insights from previous design and production experiences. As more advanced lifecycle stages approach, the twin’s talent for obsolescence management comes into its own. With this insight it also means that we can begin to introduce preventative maintenance.

Using a digital twin reduces the cost and risk involved in developing and implementing new machines by decreasing the most time-consuming aspects of building products in the real world. We can carry out a similarly exhaustive range of tests as they would by using traditional methods but without the need for physical prototypes.

Our machine is powered by digital servo drives and there are no analogue motors & gearboxes and no pneumatics. Digital drives are much more reliable, precise & accurate compared to analogue motors.  This gives the TrakRap machine world class reliability and flexibility with Mean Time Between Failure measured in decades rather than years.

The machine only requires one size of film which is simple and easy to replace and through the TP700 comfort HMI user interface, makes pack size changes typically take under 5 minutes.

In collaboration with the Manufacturing Technology Centrew (MTC) and Siemens we worked together to build a digital twin that initially helped us to identify why our system could not wrap aerosols effectively. From there we recognised its invaluable benefits to food manufacturers.

A digital twin is a precise, 3D virtual model of our machine which enables us to design, commission, test and resolve problems virtually – we can work with other machine manufacturers to simulate production lines and even whole factories, eliminating potential problems before installation.