Master Production, a niche but highly progressive machine building company from Slovenia, is tapping into the solutions and expertise of SMC to help it drive even more energy efficiencies for customers in sectors such as food and pharmaceutical. With the assistance of SMC, modifications to a cartoning machine for a nutricosmetics manufacturer support use at lower operating pressure, reducing running costs by an impressive 27% a year. As part of a total solution spanning primary, secondary and tertiary packaging processes, Master Production also turned to SMC for a new nitrogen blow solution where the adoption of flow regulation technology is minimising costs.
With electricity prices high and plants in the process sector looking to reduce running costs, the need for energy efficiency has never been greater. For Master Production, which prides itself on industry differentiation, going the extra mile is paramount. From its facility in Ajdovščina, this forward-thinking machine builder combines simplicity, effectiveness and innovation into its solutions. The family-owned company specialises in the design and build of automatic palletising and de-palletising machines, packing machines, and horizontal/vertical cartoning machines, to list but a few.
Master Production horizontal cartoning machine
Looking to make further gains in energy efficiency, Master Production turned to the expertise of long-standing automation partner, SMC.
“A project involving a horizontal cartoning machine for a nutricosmetics manufacturer provided us with the ideal opportunity to see what gains might be possible,” says Matej Puc, Chief Technology Officer at Master Production. “Top of the priority list was reducing the operating pressure of the machine’s secondary packaging operation.”
Resetting the bar
The process involves the packing of bottles filled with liquid into boxes/cartons at a rate of 10,000 per hour (equating to 700 cartons per hour). Although reducing the operating pressure was the ultimate ambition, there could be no compromise in productivity or safety.
SMC specialists in compressed air energy efficiency visited Master Production in the summer of 2024 to discuss the optimal way forward.
“We set about assessing the machine and its functionality, checking each stage of the process in detail to calculate the extent that it might be possible to reduce the operating pressure,“ explains Jan Matko, Specialist for Energy Efficiency at SMC Slovenia.
Much of the cartoning process relies on pneumatic components, with around 30 actuators per machine comprising a mix of guided cylinders that protect against damage from lateral forces, and single-rod cylinders for low-force tasks like box folding.
Says Matej Puc: “From their intensive review process and proven calculation models, SMC concluded it was possible to specify smaller cylinders in many instances. Even with a factor of safety, we could reduce cylinder size by around 20%.”
Compact cylinders from SMC require less air and perform the same function effectively at lower working pressure. End users can subsequently lower the system pressure of their compressor, reducing running costs.
SMC´s Compact Guide Cylinder – MGP Series
SMC also recommended new rotary actuators for secondary packaging processes such as bottle orientation. Again, using SMC’s know-how and experience, the team could propose the adoption of smaller rotary actuators in many instances.
Among key SMC products helping facilitate the transition to lower operating pressure was the CQ2 series, a space-saving cylinder with a compact body that offers the potential to mount auto switches on any or all of the four surfaces. SMC also supplied MGP series compact guide cylinders and CRB2 series vane-type rotary actuators. Further components included double-acting ISO piston-rod cylinders, pin cylinders, air preparation units, vacuum pads, fittings and more.
SMC´s abrasion resistant vacuum pads for corrugated cardboard transfer – ZP3C Series
Put to the test
To assess the results, the SMC team and Master Production conducted trials on the modified horizontal cartoning machine at the end user’s factory. The tests involved first running the machine at standard 6 bar pressure, then at 4.5 bar. Results were nothing short of impressive.
SMC’s team of expert professionals was able to extrapolate the figures collected to represent running the machine 24 hours a day for 286 working days per year. At 6 bar pressure, tests showed the cartoning machine to consume 13.2 m³ of compressed air per hour, or 90,605 m³ per year. In contrast, when running at 4.5 bar, the machine consumed just 9.6 m³ of compressed air per hour, or 65,894 m³ per annum. The lower operating pressure will therefore reduce the consumption of compressed air at Master Production’s customer by a notable 24,711 m³ every year.
To provide some financial context (based on current rates in Slovenia), consuming 90,605 m³ of compressed air when running the machine at 6 bar for one year would equate to a cost (for compressed air only) of €3,624. By running the machine at 4.5 bar and reducing annual consumption to 65,894 m³, cost will reduce to €2,636, representing a significant 27% saving. This is, of course, for just one machine. Imagine the savings from a production hall full of machines running at lower operating pressure.
The trials performed at Master Production’s customer also indicated the same 27% reduction in CO2 footprint. By reducing the machine’s operating pressure from 6 bar to 4.5 bar, the end user can expect to cut its generated CO2 from 5,309 kg-CO₂e to 3,861 kg-CO₂e, an important factor in the new era of European Sustainability Reporting Standards (ESRS).
Blow away inefficiency
Providing testimony to SMC’s capabilities as a single-source automation solution provider, the company also met Master Production’s requirements for a new blowing application, this time for a primary packaging process involving the transfer of the powder product into bottles.
As nutricosmetics are oral supplements, this process needs to take place in an inert atmosphere using nitrogen as the surrounding gas. Inert gas blanketing has the effect of displacing oxygen and CO2, making it particularly crucial for preserving perishable products like food and pharmaceuticals.
“We knew SMC would have a solution to help us minimise nitrogen use and save money,” states Matej Puc. The solution arrived in the form of an SMC flow controller that regulates nitrogen blow. With the flow controller in place, the end user can start, adjust and stop the flow of nitrogen as necessary. “SMC supplied a complete solution, comprising a 2/2 open/close valve, nozzles and tubing to suit our primary packaging application.”
SMC´s nitrogen blow compatible 2-port valve – HF1B-JSX Series
David Matoh from SMC Slovenia adds: “Regulated flow capability is advantageous because it avoids the common industry solution of blowing nitrogen continuously, which is both wasteful and costly. It’s even more expensive in applications involving food and pharmaceuticals, which demand the use of high-purity nitrogen.”
Compared with a continuous blow system, SMC estimates that its regulated flow solution will save at least 50% in nitrogen consumption, likely even more.
SMC´s Flow Controller – PFCA Series
Driving savings in the consumption of compressed air and nitrogen is not only great for the end user and the environment, but also for the machine builder. Master Production can use these selling points as a competitive advantage in its drive for growth and more market share.
“SMC is a supplier that stood by our side from the very beginning of our business journey,” says Matej Puc, Chief Technology Officer at Master Production. “SMC and the team are problem solvers, confident in consulting solutions and a reliable on-time supplier. We have always seen our collaboration with SMC as a long-term partnership.”
Master Production´s CTO, Mr. Matej Puc presenting horizontal cartoning machine
With this project, Master Production is demonstrating its credentials as a market innovator and early adopter of technologies that facilitate the transition to lower machine operating pressure. Following its success with the cartoning machine, the company is now looking to expand this initiative to future machine builds.
