Why automated packaging equipment manufacturers need RFID integration
High-speed packaging equipment is critical to industries such as food, produtos farmacêuticos, and consumer goods, but manufacturers face serious challenges:
- Labeling errors: Manual inspection speeds exceed 500 pieces per minute, risking recalls and fines.
- Speed bottlenecks: Barcode scanning limits throughput to 2,000-3,000 pieces/hour.
- Compliance gaps: Untraceable batches do not meet FDA, EU FMD or GS1 standards.
RFID integration solves these challenges by:
- Automating 100% item verification at over 10,000 pieces/hour.
- Reduces mislabeling costs by up to 90% with real-time data verification.
- Ensures end-to-end traceability for audits and recalls.
Competitive Advantage You’ll Gain:
- Provides embedded RFID systems for Industry 4.0 packaging equipment.
- Becomes a leader in high-speed, error-proofing automated packaging equipment.
Challenges Solved by RFID Integration
1.Mislabeling and Product Mix-ups
Issue: Human error in SKU labeling costs mid-sized manufacturers over $100,000 por ano.
Solução RFID:
- UHF RFID tags are embedded in packaging materials during production.
- Tunnel readers are used to verify tags at 10 m/s to ensure correct labeling.
2.Speed Limitations of Traditional Systems
Issue: Barcode scanner throughput is capped at 3,000 pieces/hour, resulting in order backlogs.
Solução RFID:
- Deploy UHF RFID on vertical form fill seal (VFFS) machines for batch scanning.
- Achieve speeds of more than 12,000 pieces per hour without slowing down the line.
3.Compliance and recall risk
Issue: Manual tracking does not meet serialization requirements (ex.. EU foot and mouth disease).
Solução RFID:
- Store unique serial number, expiration date and batch ID on high memory tags.
- Automatically synchronize data to ERP/MES systems via RFID middleware (ex.. Siemens RF650R).
[Contate-nos] Get RFID industrial tags for carton formers, case packers, frozen food packaging lines, liquid canning and capping machines, heat sealers and other packaging equipment
How RFID integration with packaging equipment works:
1.Hardware setup:
- Tags RFID: Encoded and embedded in labels, films or caps during production.
- Leitores RFID: Fixed tunnel readers or integrated into rotary fillers.
- Control system: Synchronize RFID data with a PLC (ex.. Beckhoff CX9020) via EtherCAT.
2.Data Flow:
- Tags encode product data during the packaging process.
- Readers scan tags at key checkpoints (por exemplo, Vedação, labeling).
- Tag mismatches trigger a reject arm or alert via an HMI dashboard.
Software Integration:
- Middleware: PTC ThingWorx or Siemens RF650R for real-time analytics.
Estudo de caso: Beverage Canning Line
A packaging equipment manufacturer integrated RFIDHY RFID tags with a Krones Linapac filler to achieve the following goals:
- Reduce mislabeled cans by 98% at a capacity of 20,000 cans per hour.
- Reduce audit time from 8 horas para 30 minutes with RFID-driven reporting.
(Customer details have been anonymized to protect privacy.)
Ready to upgrade your packaging equipment system?
We can provide:
RFID integration services for fast packaging systems
The best RFID systems for fast packaging lines
UHF RFID services for automated packaging
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FAQs
Q: How do I place RFID tags on flexible packaging?
A: Use thin, flexible tags, such as RFID inlays, that integrate seamlessly with the film.
