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Complete line with blister packaging and cartoning machines. The implementation of a B&R complete solution increased production to 600 blister packs and 300 cartons per minute. Customized panels (left) depict the entire process.

High-speed, precise product throughput in a packaging process requires a control system that is both powerful and reliable. By integrating B&R technology into their latest line of blister pack machines, Hoong-A enjoys continuous reliability while achieving production speeds of up to 600 blister packs per minute.

Based in Bucheon, South Korea, Hoong-A Corporation specializes in the manufacture of blister pack and cartoning machines for pharmaceutical use as well as a wide variety of in-feed and automated packaging machines for confectionery, household and health care products.

With a product output of 600 blister packs per minute, the new HM600R blister pack machine is one of the Korean provider's most innovative machine generations yet. Featuring a lateral punching speed of 300 cycles per minute, dual lane architecture and the latest B&R servo technology, these machines combine exceptional productivity with incredible precision. Fast format changeovers are possible by selecting preset parameters for specific formats using advanced PC technology, allowing the machine to handle a wide selection of blister packaging materials such as PVC, PVC/PVDC, PVC/ACLAR, PP and COC in addition to aluminum for cold forming.

The use of B&R ACOPOS servo drives and a powerful PC-based control system ensures fully automatic operation and a maximum degree of usability. Even the machine's operating manual is stored for the operator's convenience. In addition, the new horizontal punching system results in perfect blister discharging and easy integration of in-line blister pack production. "A powerful B&R servo drive provides extremely precise positioning on the discharge conveyor," explains Kang-Sun Lee, application manager at Hoong-A. "This allows the punched blister packs to be transferred via the discharge wheel and positioned onto the discharge conveyor with the highest speed and accuracy."

An important requirement for the new HM600R was that it be built in accordance with Good Manufacturing Practice (GMP) standards for the pharmaceutical industry. An important feature implemented with B&R's help is the machine's balcony-style structure that allows complete visibility for inspection in addition to easy maintenance and cleaning.

Cooperation with B&R has allowed Hoong-A to equip several machine series with B&R's PC-based control system, eliminating the need for additional control systems that can easily complicate the overall process. Programming, simulation, commissioning and maintenance of all the different machine types is handled using a single software tool, Automation Studio. "B&R hardware, wiring and programming are all handled in the same way," explains Lee, "and the ability to add optional machine components in a single project has considerably simplified series production and the software engineering that goes along with it."

High-performance synchronization of up to 13 servo axes in Hoong-A machines is the most important requirement for ensuring high productivity and top quality when packaging pharmaceutical products. It is also important that the axes are able to be synchronized differently when changing over to different products on the fly, especially when options such as "No product, no foil" are enabled. Hoong-A also takes advantage of features such as registration mark control and foil tension control, which are integrated in the powerful B&R drive system and implemented using dedicated and flexible PLCopen function blocks. Many of these function blocks are executed directly on the drive itself, improving response time substantially.

The perfect balance between hardware and software allows Hoong-A customers to profit from a customized packaging solution. "The ability to reuse customized software libraries made it possible for us to drastically reduce development time," says Lee. "In addition, we chose POWERLINK as our real-time communication protocol to ensure optimum drive synchronization and to increase the overall performance and precision of the machine. This turned out to be a huge advantage in handling our complex motion applications."