5 Reasons to Use Linear Motors for Packaging Applications

Linear motors are revolutionizing the packaging industry, accelerating efficiency and offering a cost-effective solution. Traditionally, pneumatics and hydraulic-driven actuators have been the mainstay for automation in this sector. However, electric linear actuators are now taking their place, offering numerous benefits in terms of performance and functionality. From processing the raw product to packaging the finished product, there are several stations that can be automated and optimized with the help of electric linear actuators.

Linear Actuators Automating Packaging and Processing Stations

	Conveying, Feeding & Handling: Linear actuators can adjust the length and position of conveyor sections, regulate the speed at which the products move along the conveyor, and shift products from different stations. Precise control ensures the correct amount of product is being fed at the right speed, in the right direction.
	Labeling & Printing: In automated labeling systems, linear actuators can move labels from dispensers to packaging at high speeds with exceptional speed, accuracy, and repeatability. Easily integrated with conveyor systems to move packages to labeling or printing stations, they can control speed and positioning to ensure the product is aligned and waste is minimized. No matter how irregular the shape, ORCA™ motors force feedback ensures sufficient pressure is applied to varying products when securing labels, enabling precise motion every time.
	Bagging, Pouching & Wrapping: Accurate product positioning for bagging or wrapping relies on precise linear motion. Electronic motors excel at managing the movement of bags through multiple stages, such as opening, filling, and sealing. ORCA motors can even accurately measure and calculate the weight of a product during the filling process and final stages, thanks to integrated force feedback. For wrapping applications these electric motors can adjust the position of wrapping heads/film dispensers, with adaptability that allows the equipment to handle different sizes and shapes of products ensuring that wrapping is snug and secure every time.
	Inspection & Testing Equipment: High reliability and repeatability is critical for accurate testing and in high-volume facilities. Their adaptability allows for the adjustment of testing parameters, such as changing the distance between inspection tools and products to accommodate different product sizes and types.

ORCA Series Smart Linear Motors combine the following attributes into their all-in-one solution where all auxiliary components including motor drivers, controllers, sensors, and more are built directly into the solution. 

The Benefits of Industrial Linear Actuators in Packaging

Unlike hydraulic and pneumatic actuators, electricity driven actuators feature no oil pumps or energy-intensive compressors. The DC electric motors eliminate the need for hydraulic fluids which can leak and require regular replacement, and avoid air leaks and pressure regulation issues associated with pneumatic systems. Designed to run millions of cycles and more, electric linear actuators have fewer components prone to wear and tear. In fact, ORCA motors only have one single moving part. The simplicity of their design offers reliability and significantly reduces maintenance requirements and costs. At the end of its lifetime, simply replace the two bushings at each end of the stator and the system will be up and running in a matter of minutes. Greater reliability leads to less downtime and operational disruptions involved in regular maintenance and repair. Even more notably, a reliable system results in lowered operational costs. An ORCA motor will pay itself off within a year when replacing pneumatic actuators. With energy costs accounting for two-thirds of pneumatic systems operating systems, and compressed air being one of the most expensive energy sources, the switch to electric motors shows clear savings. 

Ideal for dynamic and evolving production environments, electric linear motors offer unparalleled versatility, exceptional reliability, and rapid adaptability. Their modular, direct drive design facilitates seamless adjustments in speed, position, and force, allowing for swift reconfiguration of production lines to accommodate various product specifications. With fewer moving parts, electric linear motors have a longer system lifespan and lower maintenance needs, making them both robust and dependable. This increased reliability guarantees consistent performance and minimizes production interruptions. In contrast to traditional systems that often require extensive reconfiguration or new infrastructure, electric motors can be integrated or adjusted with minimal disruption. This combination of adaptability and reliability ensures that production lines can efficiently scale operations and stay responsive to ever-changing market demands without sacrificing operational efficiency.

Whether you’re aligning containers, positioning labels, or managing filling process positioning, accuracy and motion control is crucial. With integrated force and position sensing, electric linear motors enhance precision and accuracy by delivering consistent, repeatable movements with minimal error, resulting in high reliability. High-resolution feedback and fine control over position, velocity, and force, allows for precise adjustments and consistency in tasks like sorting, aligning, and packing products. In turn, errors are minimized, waste and damaged products are reduced, and product quality and overall efficiency in high-speed and high-precision applications are increased. Their direct drive design eliminates mechanical backlash and wear, ensuring that each operation is performed with the same standards every time. This precision allows for dependable performance in tasks such as product positioning, where even minor deviations can lead to significant issues. 

The lower total cost of ownership (TCO) refers to the overall expenses associated with the system throughout its entire lifecycle, from purchase through operation and maintenance, to the eventual replacement or disposal. In terms of electric linear motors, a lower TCO means that not only is the initial purchase cost relatively low, but ongoing operational and maintenance expenses are also minimized. This includes savings from reduced energy consumption, lower maintenance needs, and fewer repairs due to the motor's reliable and durable design. The humble electric motor has a simple design, fewer moving parts susceptible to wear and tear, providing them with a longer lifespan than hydraulics and pneumatics which require regular maintenance and result in shorter lifespans. Ultimately, a lower TCO highlights the cost-efficiency of the motor, making it a more economical choice over time.

Easily integrate an electric linear actuator into your facility to boost productivity, throughput, while maintaining a quiet working environment. High speed motors such as ORCA motors, handle high loads at accelerated speeds up to 3.8 m/s (148 in/s) allowing for rapid processing and handling of products while boosting throughput and maximizing cycle times. Higher volumes of products can cycle through the production lines quicker, reducing bottlenecks and lead times. However, speed isn’t everything. You can have the fastest solution in the world that in return generates high levels of noise pollution and creates an unsafe working environment.  Nearly 20% of manufacturing workers suffer from hearing difficulties, with prolonged exposure only worsening employees' conditions. With the introduction of electric linear actuators, there is the potential to drastically decrease noise pollution, especially in comparison to their counterparts, hydraulic and pneumatic systems. Most linear actuators are rated below 65 decibels which is considered to be fairly quiet. ORCA motors’ are as silent as 20 decibels, which is comparable to the noise level of a whisper. In high-volume production areas, it is crucial to minimize noise pollution when able.  

From efficiency, to cost-savings and adaptable solutions - electric linear motors are transforming the packaging industry. With unparalleled precision, rapid and quiet operation, minimal maintenance needs, and lower TCO, they far surpass traditional methods such as pneumatic and hydraulic systems. These electric actuators can easily be integrated into your existing equipment and can help to automate various tasks. If you are seeking an electric linear actuator for your packaging and processing applications, consider Iris Dynamics. The company specializes in designing and manufacturing linear actuators which are fully-integrated, meaning all auxiliary components such as sensors, drivers, and controllers are built into the solution. With centralized sales and support, Iris Dynamics is happy to discuss your requirements - contact a sales representative here.