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Blog

Universal Invests In Customer Technology Centre

August 18, 2022 by Alan Jones

Universal has recently purchased an additional building close to its production operation. The building is currently undergoing refurbishment and decoration. The building will be equipped with the latest machinery from Universal and will be a dedicated demonstration facility for customers to see how this technology will deliver real benefits to their businesses.

Commenting on the investment, Alan Jones, Director of Universal Converting Equipment said “We have invested heavily in developing class leading slitting and winding machines. Many of the developments have never been seen before by our customers. This new facility will create the best environment to demonstrate this exciting new technology away from the production halls. Although we can explain to customers the benefits of our automation and control systems, demonstrating it by running the customer’s material with them watching is far more powerful.”

Filed Under: News

FFP Packaging Solutions win ‘Investment of the Year’ at UK Packaging Awards with the Universal X6

January 24, 2022 by Alan Jones

FFP Packaging Solutions has won the prestigious ‘Investment of the year’ award at this years UK Packaging Awards. FFP is a packaging company that focuses on designing and manufacturing sustainable packaging solutions for food, beverage, pharmaceuticals and other industries.

Established over 50 years ago, FFP have grown to become one of the leading flexible packaging suppliers in Europe with many distribution sites across England, Scotland & Wales.

Their products are designed to help businesses grow by increasing efficiencies while reducing costs through innovative design solutions tailored to their customer’s needs. FFP have significantly invested in new machinery, including a Universal X6 Slitter, which has led them to winning the ‘Investment of the year’ award.

An FFP representative explained,
“In October 2020, we commissioned our latest investment, a new laser system which is a collaboration between Coherent and Universal Converting Equipment.

The new machine consists of a high productivity slitter from Universal Converting Equipment combined with a state-of-the-art laser machine from Coherent. This new machine represents an investment of £700,000 for FFP and has significantly enhanced our laser profiling capability and increased capacity.

Not only has the new equipment had a huge impact on the capacity of the factory allowing us to respond to customer and market demand, but it also brings with it enhanced capabilities and efficiencies.”

The positive profile of the Universal X6 continues to develop at a pace in the Flexible Packaging industry, due to a reputation for speed, reliability and many eco-aware features. When integrated with laser equipment from Coherent the Universal X6 is able to score, inspect and slit at speeds that leave competitive machines behind.

The UK Packaging Awards judges noted that,
“A great combination of investment in machinery, increasing capacity, and sustainability with the Esterseal development. Marvellous work!”

Everyone at Universal Converting Equipment would like to congratulate FFP Packaging Solutions on winning this important award. If you would like to find out more about how the Universal X6 can increase efficiency and reduce costs please contact us.

Universal X6 Slitter Rewinder

Find out more about FFP Packaging Solutions…

Find out more about the award on the Packaging News website…

Filed Under: News Tagged With: ffp, slitter, slitter rewinders, Universal X6, X6

Coveris increase BOPP capacity with Universal X6 Slitter Rewinder

January 6, 2020 by Andrew Laws

Flexible packaging manufacturer Coveris have revealed details of a program of investment that has led to a significant increase in production of BOPP (Biaxially-Oriented Polypropylene) labels.

As reported on the Labels and Labelling website Coveris have announced a large increase in productivity in their BOPP label manufacturing capabilities at their facility in Louth (UK). The company, who supply bottle labels to companies including Coca-Cola and Refresco, supported this growth by purchasing a fully automated Universal X6 Slitter Rewinder.

The quality of labels produced at the Louth facility was recently recognised by the European Flexographic Industry Association (EFIA), who gave Coveris a Gold award in the ‘Flexo Print on Film – Reverse Print Narrow’ category in 2019.

The fully automated Universal X6 Slitter has been installed in the dedicated finishing hall at Coveris Louth. The Universal X6 is a part of a program that has seen the site’s capacity to over 3 billion labels per year.

‘Coveris is uniquely positioned as the leading supplier of plain and printed films to the beverage sector in Europe. Supported by investment in state-of-the-art technology, dedicated BOPP manufacturing capabilities and award winning print, we are able to provide our customers with leading quality, service and products, while targeting ambitious growth in the BOPP beverage industry,’ said Mark Summers, Coveris Films Sales Director.

Universal X6 Slitting machine

Filed Under: News Tagged With: slitter rewinders, Universal X6

ACL Films launch new website

December 9, 2019 by Andrew Laws

Universal Converting Equipment customers ACL Films Pty Ltd are celebrating the launch of a new website. Based in the state of Victoria, Australia, and operating worldwide, ACL Films are a family owned and managed business. The company offers specialist slitting, die cutting and sheeting services in addition to supplying a wide range of films.

In 2015 ACL Films upgraded their capabilities by investing in a Universal X6vt Slitter Rewinder and a Universal CCA Automatic Core Cutter. The machine is proudly displayed on several pages of the new website.

ACL offer contract slitting to many different industries, giving them a deep level of slitting expertise. The company slits a broad range of quantities and materials, so being able to set up a variety of slitting jobs in a minimal amount of time, and reducing waste meant the Universal X6 was the perfect machine for their expanding customer base.

The new website highlights ACL’s dedication to fast production turnaround, without compromising on quality or customer service. The Universal X6 is one of the fastest slitters on the market today, not just in ‘metres per minute’ speed, but also in terms of incredibly fast job setup. Automatic knife setting, core loading (and positioning) are just some of the automation features that make the X6 such a popular machine.

To find out more about ACL Films Pty Ltd visit https://www.aclfilms.com.au/

ACL website image

Filed Under: News Tagged With: slitter rewinders

InfoFlex 2019

April 29, 2019 by Andrew Laws

We are pleased to announce that we will be exhibiting at InfoFlex again this year. InfoFlex is hosted by the Flexographic Technical Association (FTA). InfoFlex is being held from May 6-7 2019 at the Ernest N. Morial Convention Center in New Orleans.

2019 is already a record year for Universal Converting Equipment, following on from an exceptionally successful exhibition at ICE 2019 we are looking forward to the opportunities that exhibiting at InfoFlex 2019 will bring.

At Infoflex 2019, we will be unveiling a range of additional automation systems to further reduce operator input required in setting and running the Universal X6 slitting machine.

Please contact us if you would like to book an appointment to speak with us at InfoFlex in New Orleans.

infoflex 2019 logo

Filed Under: Events

Universal X6 Slitting Machine Designed for Industry 4.0 Factorywide Integration

March 12, 2019 by Alan Jones

Industry 4.0 is an industry ‘hot topic’. It is being discussed alongside the ‘Internet of Things’ (IOT) as the future for process equipment, allowing integration of a range of processes that facilitate and improve data sharing.

Industry 4.0 is not a new concept. It originated in 2011 as a way of fusing the online world with the world of industrial production. Correctly implemented, Industry 4.0 it will drive future productivity growth for each company that invests in the technology.

The four principles behind Industry 4.0 are:

  • Interconnection
    Communication between machines, devices, sensors and people – for example using the Internet of Things (IOT) or the manufacturing equivalent; ‘Industrial Internet of Things’ (IIOT). This technology enables devices to collect and exchange information.
  • Information Transparency
    Visibility of data from a range of processes to provide accurate information for management, empowering intelligent productivity and innovation strategy. For example, information on Overall Equipment Effectiveness (OEE) made instantly available to decision-makers.
  • Technical Assistance
    Firstly, the ability of assistance systems to support humans by aggregating and visualizing information comprehensively, for making informed decisions and solving urgent problems at short notice. Secondly, the ability to physically support humans by conducting a range of tasks that are unpleasant, exhausting, or unsafe for their human co-workers.
  • Decentralized decisions
    The ability of industrial systems to make decisions on their own and to perform their tasks as autonomously as possible. Only in the case of exceptions, interferences, or conflicting goals, are tasks delegated to a higher level for human input.

The principles of Industry 4.0 run parallel with concepts already in use by Universal for the strategic direction of the development of converting machinery. The concept of intelligent design working symbiotically with human operators together with the transparent flow of information, streamlining productivity and enhancing profitability has been core to the development of machinery at Universal for well over five years.

Why use people to do tasks that are better done by machines?

Industry 4.0 slitter

Linked to specific automation systems, significant productivity improvements are being achieved. Some examples of Industry 4.0 development in practice are as follows:

MQTT Communication Protocol
The IIOT requires devices to communicate with one another and exchange data. In order to effectively communicate with a wide variety of different devices, MQTT (Message Queue Telemetry Transport) becomes a standard communication protocol in IIOT.

The Universal X6 and X6 VT slitting machines support MQTT. This communication protocol is a lightweight publish/subscribe messaging protocol for M2M (machine to machine) communications and is already being widely implemented in different application service such as Facebook messenger, and Amazon web service.

Unlike traditional request-response polling protocols such as HTTP or Modbus, MQTT is based on the principle of publishing messages and subscribing to topics, where every HMI publishes messages to a MQTT server that functions as a broker. Every MATT message is also classified by one topic. In this manner, the MQTT broker is capable of reliably and precisely sending the message out to those clients who have previously subscribed to this topic. With the capability of communicating over 250 major manufacturers of PLC and controller, the Universal X6 efficiently integrates diverse data between different devices and effectively publishes needed data to the MQTT broker.

OPC UA Communication Protocol
OPC UA (Open Platform Communications Unified Architecture) is a communication technology often used in industrial automation fields. It simplifies communication between higher level devices such as a Universal X6 slitting machine and the customer’s Management Information System (MIS). OPC UA features cross-platform interoperability, unified access, standardized communication, and security.

In this architecture, the Universal X6 with built-in OPC UA server plays a key role as Communication Gateway, and allows OPC UA clients to access HMI or PLC data by subscribing to tags to receive real-time updates. OPC UA can be used to transfer recipe or product data to the Universal X6 from a customer database with quality and productivity data being sent in the other direction.

SQL Database Integration
Structured Query Language (SQL) is a standard system for managing data held in relational databases. Equipped with easy-to-use database integration, the Universal X6 can send machine metrics, production data or recipes to a database system directly without any middleware system. This data can then be managed in a larger scale using batch database operations. Plus, the built-in database-related viewers enables smooth operations using data on the databases. These features can simplify your processing works and save your precious time.

Collecting machine metrics is always a challenge for integration. In the past people used USB drives or FTP services to retrieve files (such as CSV files) from a machine, convert the file formats, and then save them to separate tables or spreadsheets. This cumbersome work can get compli­cated once more files or more machine metrics are added to the system. A better option is to save machine metrics directly to a database. This has several benefits includ­ing simpler batch operations, no more file conversion, more storage options, and spaces, and finally, use intuitive SQL commands to customize your read/write/modify/delete operations on the database.

The Universal X6 built-in database integration can send real-time machine data, alarms and events to databases, and this data can also be displayed on HMIs or remotely (PC/mobile re­mote-control app). This can be done without writing any program code, an easy database solution. After saving the data into databases, IT/MIS experts can further analyze and make decisions based on those data, such as report generation, energy usage, manufacturing record tracking.

The SQL Query feature provides a more general way to access databases. It can send and change recipes in a database like a shared Recipe Database when multiple machines use the same recipe. Batch recipe change can be applied to all machine at once using databases. SQL Query also accepts customized SQL commands for filtering and statis­tics, such as OEE calculation (Overall Equipment Effectiveness), unit production rate, averag­es of numbers, standard deviations, etc.

Machine Diagnostic Systems
The Universal X6 has extensive diagnostic systems translating data from all the devices on the machine into simple to use fault diagnostics. The Live electrical drawings show the status of all the inputs and outputs to the system for detailed diagnostics. Machine use data allows knife life to be measured and if required, the machine can indicate when knives should be changed.

Secure Remote Communication
The Universal X6 uses a secure 128 bit SSL encryption mechanism, as commonly used for on-line banking, to ensure the reliability of its remote data transmission. When connected remotely, a Universal engineer can connect to all the drives and HMI’s on the machine for real time diagnostics. The same connection can be used to remotely view the machine operation on tablets, mobile phones and PC’s.

Replacement of Operator Tasks
As companies strive to improve the OEE of their processes, one option is to increase the level of automation. The Universal X6VT has a number of linked automation systems allowing the machine to set most of the parameters required for a job change. Automatic guider sensor positioning, automatic knife positioning (razor and rotary shear), automatic roll unloading and automatic core loading and positioning are standard. These minimise the time taken to change between one order and the next as well as minimising the stopped time between sets of rolls. As well as dramatic productivity gains, there are other benefits as well. Health and safety is improved as knife handling is reduced and repetitive tasks such as pushing cores onto differential shafts and locking in position are removed. Quality also improves as the knives and cores are always placed in the correct position.

Machines Designed for the Future
Universal Converting Equipment has been building slitting and rewinding machines for a long time. The thinking behind Industry 4.0 follows the development route already chosen by Universal. The four principles described at the start of this article are evident in a lot of the detail contained in the Universal X6 slitter range. In particular, the Universal X6VT has a comprehensive automation and communications package as standard.

Filed Under: Technical development

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