Efficient maintenance thanks to condition monitoring
Schreyer Sondermaschinen increases the efficiency and availability of its packaging solutions through intelligent drive technology and smart condition monitoring – with system solutions from WITTENSTEIN.
Monitor packaging processes digitally – with smart gearboxes and Smart Services
The demands for process stability and efficiency in the packaging industry are constantly increasing. Manufacturers such as Schreyer Sondermaschinen GmbH therefore rely on digital solutions from WITTENSTEIN: Smart CPK right-angle gearboxes with cynapse® function provide valuable status data in tubular bag machines. In combination with the smart service cynapse® Monitor, this results in powerful condition monitoring that reduces downtime and increases machine availability.
Digitization of packaging machines creates real added value
Schreyer Sondermaschinen GmbH, based in Auenwald, develops customized packaging solutions – especially for the food industry. As the European market leader in pizza lines, Schreyer packages up to 250 frozen pizzas per minute.
Tubular bag machines ensure high precision – even with ultra-thin foil measuring just 8 to 10 micrometers.
The insert of smart gearboxes and Smart Services from WITTENSTEIN alpha can become a unique selling point for the company on the market.
Challenge: Ensuring process stability during film cutting
In the cross-sealing station of tubular bag machines, precise adjustment of the cutting blades is crucial. Integration into hot sealing jaws (95–110 °C) causes thermal expansion, which can impair the cutting quality. Incomplete cuts lead to packaging errors and potential machine downtime. Until now, it has not been possible to detect maintenance requirements at an early stage.
Smart gearboxes for digital machine monitoring
With CPK right-angle gearboxes and integrated cynapse® technology, WITTENSTEIN offers a compact solution for condition monitoring directly in the gearbox. Temperature, vibration, and acceleration values are recorded and transmitted to the control system or cloud via IO-Link and OPC UA.
The Smart Service cynapse® monitor automatically analyzes the data, detects limit value deviations, and enables early maintenance planning. This saves programming effort, increases machine availability, and supports predictive maintenance – in line with Industry 4.0.
Our products in use at Schreyer Sondermaschinen
CPK
A CPK hypoid gearbox from the alpha Basic Line from WITTENSTEIN alpha is inserted in the axle of the film dispenser.
cynapse®
The cynapse® module in the CPK gearbox can measure and evaluate vibrations and peak-to-peak acceleration values in addition to temperature values.
Gain insight into operating behavior with cynapse® Monitor
Smart Service can take over and evaluate the recorded operating data. The integrated teach-in function is able to record the vibration and acceleration behavior over a defined period of time, as is typical for an I/O cross-sealing group. The software can determine and monitor individual limit values for the operating behavior of the cross-sealing station and the blade setting. The visualization of the current measured values can then be integrated into the machine's user interface and thus made directly accessible to the machine operator or service personnel. It is also possible to prepare all data as histograms and store them in the gearbox history. Schreyer Sondermaschinen is well on the way to working with WITTENSTEIN alpha and an end customer to implement automated detection and forecasting of maintenance requirements for the film cutting knives in the cross-sealing station.
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