How to optimize your packaging lines with motor-mounted Gear Boxes from ATEK
What are the main advantages of motor-mounted inline Gear Boxes in packaging machines?
They offer high precision for exact movement sequences, a compact design for tight spaces and efficient power transmission. This can increase productivity and reduce cycle times by up to 15%.
How do inline Gear Boxes contribute to reducing total operating costs (TCO) in packaging lines?
By simplified assembly, as the motor and Gear Box are often supplied as a tested unit (which can mean up to 20% time savings) , high energy efficiency with efficiencies often exceeding 95% and lower maintenance effort due to the possible elimination of couplings.
What should I consider when selecting an inline Gear Box for the food or pharmaceutical industry?
Crucial are hygiene-compliant materials such as stainless steel, special corrosion-resistant surface treatments (comparable to nsd tupH) and high protection classes (e.g. IP69K). These ensure cleanability and compliance with industry standards.
Can ATEK provide customized inline Gear Box solutions for specific packaging requirements?
Yes, ATEK specializes in the development of customized special solutions , even in small batches. Our modular system allows for millions of configurations and a quick adaptation to your specific needs.
Why is decentralized control often advantageous for motor-mounted inline Gear Boxes in packaging systems?
Decentralized controls, such as frequency converters mounted directly on the motor, can reduce control cabinet space by up to 30%, decrease wiring effort, and increase the modularity and flexibility of the entire packaging system.
What role does IIoT capability play in modern inline Gear Boxes for packaging plants?
IIoT-capable Gear Boxes allow for remote monitoring and condition monitoring. This can, for example, detect bearing damage early, optimize maintenance activities, and increase the availability of the system by up to 10%.
How quickly can ATEK deliver a configured motor-mounted inline Gear Box?
Thanks to our modular system and a extensive inventory of nearly 400,000 to 500,000 individual parts, many Gear Box variants, such as specific bevel Gear Boxes, can often be configured and ready for dispatch within 48 hours. What typical efficiency increases can modern motor-mounted inline Gear Boxes achieve?
Welche typischen Effizienzsteigerungen sind durch moderne motormontierte Inline-Getriebe erreichbar?
In addition to energy savings of up to 15% e.g. through the use of IE4/IE5 motors in combination with efficient Gear Boxes, they enable shorter cycle times of up to 15% and a reduction of the scrap rate, for example by 3%, due to higher precision and repeat accuracy.
Motor-mounted inline Gear Boxes are key components for modern packaging systems, characterized by compactness, precision, and efficiency . They allow for up to 25% space savings and can reduce cycle times by up to 15%..
The selection of the right inline Gear Box leads to a significant reduction in total operating costs (TCO). This is achieved through simplified assembly (up to 20% time savings),, high energy efficiency (efficiencies >95%), and a increased durability of the drive unit.
ATEK’s modular systems and the ability to develop custom solutions offer maximum flexibility and fast delivery times for packaging applications. The integration of IIoT functions can also increase system availability by up to 10%..Learn how motor-mounted inline Gear Boxes can revolutionize your packaging systems: From faster cycle times to lower maintenance costs – we show you the benefits!
Increase the efficiency of your packaging systems with the innovative inline Gear Boxes from ATEK. Our motor-mounted solutions offer the highest precision and reliability. Discover the benefits now and contact us with our experts today!
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Introduction to motor-mounted inline Gear Boxes for packaging systems
Modern packaging systems require high speed and accuracy. Motor-mounted inline Gear Boxes efficiently transmit motor power for exact movement sequences, reducing, for example, the cycle time of a labeling machine by up to 15%. The direct motor mounting enables a compact, powerful design, a core feature of drive solutions such as the motor-mounted inline Gear Box for packaging systems. ATEK offers suitable Gear Boxes with motor flange..
A Gear Box adapts motor speed and torque to application requirements. It converts high speed/low torque into low speed/high torque (or vice versa), e.g., from 3000 rpm to 150 rpm for a conveyor belt. This adaptation is crucial for energy efficiency and lifespan of the drive unit, especially for Gear Boxes designed for packaging systems. ATEK assists in the design of drive Gear Boxes..
Compactness meets performance.
Inline Gear Boxes save space. The direct motor connection eliminates couplings and bearing points, reducing the installation length. Compact servo bevel Gear Boxes can save up to 25% space. This compactness allows for more complex functions in a small space or easier machine retrofitting, a significant advantage when motor-mounted inline Gear Boxes are integrated into packaging systems.
Precision for demanding tasks.
The highest accuracy is essential in the packaging industry. Motor-mounted inline Gear Boxes, especially servo Gear Boxes, provide high positioning and repeat accuracy. Planetary Gear Boxes achieve, for example, a backlash of less than 3 arc minutes. This precision ensures quality and minimizes material loss, a result achieved through the use of high-quality Gear Box solutions for packaging systems. Information on Gear Boxes and motors..Functioning and benefits of inline Gear Boxes in packaging machines.
Industrial inline Gear Boxes connect Gear Box stages directly and linearly to the motor shaft, unlike iMT Gear Boxes in vehicles. A multi-stage planetary Gear Box enables high ratios in the smallest space. Main advantage: linear power transmission for high efficiencies and compactness, features that make inline Gear Boxes particularly valuable for packaging systems.
Motor-mounted inline Gear Boxes optimize systems by reducing assembly effort (motor and Gear Box as a tested unit), saving time and avoiding alignment errors. Customers report up to 20% shorter assembly times per drive. This efficiency and the elimination of couplings lower the TCO, an important aspect when selecting drive systems for packaging systems. ATEK uses modern servo motors..
Modular adaptability.
A modular system allows for customized Gear Boxes without expensive special manufacturing by combining standardized components. A bevel Gear Box (15:1 ratio, specific flange) can often be delivered within 48 hours. Flexibility means fast delivery and optimal solutions, especially when it comes to Gear Boxes for diverse packaging systems.
Efficiency and durability.
High mechanical efficiencies (often >95%) of inline Gear Boxes lower operating costs. More motor power reaches the output shaft, and less energy is lost as heat. A system (10 drives of 1 kW each) saves over 200 euros in electricity costs with 2% more efficiency (6000 hours/year). Energy efficiency and robust construction mean lower operating costs and longer lifespan of the Gear motors, which serve as motor-mounted inline units in packaging systems.Selection criteria for inline Gear Boxes in packaging systems.
The right Gear Box selection is crucial. An accurate analysis of continuous and intermittent torque demand is essential. A sealing station, for example, requires 80 Nm peak, but only 30 Nm in continuous operation. Considering load profiles prevents oversizing and ensures longevity, a must when designing inline Gear Boxes for packaging systems.
- Precise analysis of the continuous and intermittent torque demand of the application.
- Consideration of the entire load profile to avoid oversizing or undersizing.
- Precise adjustment of the Gear Box output speed to the required cycle rate of the packaging line.
- Correct choice of Gear Box ratio in relation to the motor speed for optimal throughput.
- Selection of the appropriate Gear Box type (e.g., planetary, spur, worm Gear Box) based on torque, speed, space requirements, and precision.
- Use of hygiene-compliant materials such as stainless steel and special surface treatments for the food or pharmaceutical industry.
- Examination of the need for customized solutions, e.g., adapted shafts or special coatings.
The Gear Box output speed must exactly fit the cycle rate of the packaging line. A labeling machine for 120 products/minute requires precise synchronization. The coordination of motor speed and Gear Box ratio is essential for throughput and process stability, especially in high-speed packaging systems that rely on reliable motor-mounted Gear Boxes. ATEK offers powerful worm Gear motors..
Suitable Gear Box types and materials.
The choice of Gear Box type (planetary, spur, worm Gear Box) depends on torque, speed, space requirement, and precision. Servo planetary Gear Boxes are suitable for dynamic positioning tasks; worm Gear Boxes are used for high ratios in compact spaces. The optimal choice depends on the specific requirements of each packaging system.
Hygiene and customized solutions.
For the food or pharmaceutical industry, hygienic materials (stainless steel, special surface treatments such as nsd tupH) are necessary. They prevent corrosion and are easy to clean. ATEK offers stainless steel gear boxes and hygienic design that is ideal for motor-mounted inline gear boxes in packaging systems of these industries. Custom adaptations (shafts, coatings) are possible.Integration and control of inline gear boxes in packaging systems
The integration also includes control. Decentralized controls (frequency converters at the motor/motor proximity) can be advantageous, reducing control cabinet space (up to 30%) and wiring. Decentralized intelligence relieves the PLC and increases modularity/flexibility, which is especially beneficial in complex packaging systems with multiple motor-mounted drive units.
Open communication standards (EtherCAT, Profinet, Ethernet/IP) are essential for the interoperability of machine components, e.g., when connecting to upstream/downstream lines. Open standards ensure future safety and flexibility when integrating gear boxes into packaging systems. ATEK supports the selection of compact drive systems.
Safety aspects and accessories
Safety couplings (e.g., from R+W) disconnect the motor and output side in case of overload. Frequency converters provide integrated safety functions (STO, SS1). These components contribute to plant availability and longevity, especially in demanding packaging systems that rely on reliable motor-mounted inline gear boxes.
Optimal accessory selection
Accessories such as brakes (holding functions, emergency stops) and encoders (position/speed feedback) improve performance and functionality. A high-resolution 20-bit encoder increases positioning accuracy. Careful selection enables tailored motion control solutions that fully exploit the potential of motor-mounted inline gear boxes for packaging systems. Information on motor-mounted inline gear boxes.Case studies and application areas for motor-mounted inline gear boxes in packaging systems
In the food industry, inline gear boxes must be precise, easy to clean, and durable (e.g., in yogurt filling machines) – requirements that motor-mounted inline gear boxes for packaging systems can fulfill in this sector. Stainless steel gear boxes from ATEK (IP69K) are suitable for labeling machines (up to 200 products/min.). Precision and hygienic design are essential here.
- Food Industry: Use of precise, easy-to-clean, and durable stainless steel gear boxes, often as motor-mounted inline gear boxes, (e.g., IP69K) in filling and labeling machines.
- Pharmaceutical Packaging: Use of high-precision servo inline gear boxes to increase process reliability and reduce scrap rates, for example, in cartoners.
- Palletizing Systems: Realization of complex movements and efficiency improvements through decentralized drive solutions that often utilize motor-mounted gear boxes to save space and costs in packaging systems.
- Retrofitting existing systems: Retrofitting with modern drive technology, such as energy-efficient motor-mounted inline gear boxes for packaging systems, to reduce energy consumption, lower maintenance costs, and extend the machine lifespan.
- High-speed applications: Meeting demanding cycle times, such as with labeling machines with up to 200 products per minute, often achieved through dynamic motor-mounted inline gear boxes.
- Process Optimization: Significant improvements such as reducing the scrap rate by 3% in blister packaging lines by using suitable gear box solutions for packaging machines.
Pharmaceutical packaging requires maximum reliability (e.g., cartoners). High-precision servo inline gear boxes from ATEK reduced a customer’s scrap rate of a blister packaging line by 3%. Process reliability is crucial here, and using suitable gear boxes in these packaging systems is a key factor.Gear boxes with flange connection are often suitable.
Efficiency in palletizing systems
Decentralized asynchronous motors with mounted frequency converters realize complex movements in palletizing systems efficiently. Symach saved space and costs by switching to decentralized solutions (Nord Drivesystems). Decentralized architecture simplifies construction and commissioning, especially when it is based on compact, motor-mounted gear units for packaging systems.
Retrofitting existing systems
Retrofitting older systems with modern drive technology is often beneficial. A customer reduced the energy consumption of a film-wrapping machine by 18% through retrofit and lowered maintenance costs. Retrofit extends lifespan and increases competitiveness, especially by replacing outdated drives with modern motor-mounted inline gear boxes for packaging systems.Future perspectives and innovations in motor-mounted inline gear boxes for the packaging industry
The integration of drive technology into the IIoT is important for future-proof packaging systems. Modern drive solutions, including motor-mounted inline gear boxes, are often IIoT-ready, enabling remote monitoring and diagnosis. Condition monitoring can early detect bearing damage and increase plant availability by up to 10%. Networking is a building block for Industry 4.0, even in the field of drive technology for packaging systems.
Energy efficiency reduces costs and promotes sustainability. Highly efficient gear boxes (>95% efficiency) and motors (IE4/IE5+) reduce energy consumption. Switching from IE2 to IE4 motors can save up to 15% energy. ATEK focuses on energy-efficient gear box and motor combinations, which are highlighted as motor-mounted inline units in packaging systems.
Modular construction for agility
Modular design of gear boxes and motors facilitates rapid response to market demands. A large inventory enables configuration and fast delivery of many variants. The modular system supports agility, an important factor in providing motor-mounted inline gear boxes for various packaging systems.
Continuous development
ATEK invests in R&D for product optimization (efficiency, durability, compactness, intelligence). New gear tooth geometries, for instance, reduced operating noise by 2 dB(A). Innovation orientation aims for powerful, reliable drive solutions, particularly in the field of motor-mounted inline gear boxes for packaging systems.
