VAI Packaging improves productivity, efficiency and service quality with Industrial IoT

Thanks to remote access and data, machine builders can improve on-site maintenance and promote the optimization of the new generation of machines. Let's look at the example of VAI Packaging, an Italian manufacturer of packaging machines.

The Italian packaging industry focuses mainly on exports, with a share increasing according to the UCIMA (Italian Association of Manufacturers of Automatic Packaging Machines) up to 80%. This proves the high technological value of the machines produced by the Italian manufacturers. At the same time, this poses numerous challenges regarding the quality of support and service provided.

In this context, the situation of VAI Packaging is relevant. They design and produce automatic and semi-automatic packaging machines for various sectors, from food to non-food. Their customers are mainly located in the United States, Europe and Israel.

The VAI Packaging factory in Castelfranco Veneto, Italy.

Challenge

The implementation of a industrial IoT solution arises from various needs to provide customers with a solution for accurately managing production recipes. It is necessary to implement the interconnection of machines, adapted to the customers' production settings. This can be done with various tools, from simple PCs to more complex infrastructures.

Until four years ago, remote service was optional. Nowadays all our customers want to connect their machines. Federico Martalò Project Manager at VAI Packaging

“Until four years ago, remote service was optional. Nowadays all our customers want to connect their machines.”

Federico Martalò Project Manager at VAI Packaging   The main challenge for VAI's customers is the processing of large production quantities or small quantities of a large number of references. Usability and accuracy when machine recipe management therefore play a primary role.  

Solution

IXON Cloud's industrial IoT solution makes the connection between the PLC on the machine and the platform on the cloud. Here the manufacturer can view operational data of the machine park. He can then also choose which data he wants want to share with the customer via the service portal.

The technical functionalities of IXON Cloud made this type of implementation possible. It enabled VAI Packaging to realize the necessary interconnection to deliver structured remote support to provide. And to use the remote control panel for direct intervention on the required drives.

V510S HS packaging machine.  

VAI has the data dashboards adjusted and divided the machine data into two types:

• Data relating to specific production cycles (order, recipe code, bags to be produced);
• Additional data monitored in real time for statistical purposes (time interval, number and weight of bags produced), to get a global overview of the machine's efficiency.

“We have IXON Cloud installed as standard on our machines. Due to its simplicity, the solution is also suitable for retrofitting.”

Federico Martalò

Project Manager at VAI Packaging

Conclusion

Thanks to the information collected, VAI Packaging was able to optimize the operation of the delivered machines and increase productivity. In addition, they were able to reduce their consumption and a after-sales service strategy develop for their customers.