Meeting high demand in uncertain times

ECONO-PAK is a leading manufacturer of carton packaging machines, with more than 35 years of industry experience. Based near Frankfurt, Germany, they have maintained the feel of a family-run business and are able to offer a personal level of customer service. ECONO-PAK’s machines are suitable for a wide range of packaging needs across various industries and can readily be customized to meet specific customer requirements.

In recent years, ECONO-PAK has partnered with Rockwell Automation to design and build more efficient, productive, and safe carton-packaging machines. These machines were needed to meet the high demand for orders and maintain quick and efficient delivery times, especially during times of global unrest and uncertainty, such as the current crisis of availability. Rockwell Automation was able to support ECONO-PAK in this by ensuring that supplies were provided before they were needed.

Adapting to Uncertain Times

One major challenge faced by packaging-machine manufacturers in recent years has been the need for agility and flexibility. Given global economic uncertainty and ongoing supply-chain constraints, the ability to quickly pivot production is crucial in today's market. Machine builders are looking for ways to become more adaptable and able to switch between production needs based on demand. This means reducing the time it takes to switch a machine from producing one form of carton to another, as well as simplifying the process.

According to Max Schneider, international sales manager at ECONO-PAK, “We started working with Rockwell Automation around two years ago, with the goal of supporting our customers to digitalize their machinery to become more resilient to uncertainty and to be more proactive in adapting their production to meet market demand. This would require solutions that enabled quick decision-making and seamless machine change-over.”

Thanks to support from Rockwell Automation, ECONO-PAK is now able to provide machines that can meet these challenges through the use of digital twin technology, such as Emulate3D™. This software allows testing to be simulated through twinning technology, avoiding a trial-and-error approach, and creating a more efficient and cost-effective process that can be trusted to work effectively in the real world.

“The support we received from Rockwell Automation allowed us to introduce new technology in a way that was seamless for our customers, both in terms of service and technical support,” Schneider added.

Building a Safer Working Environment

Safety is also a top concern when it comes to packaging machines. Workers often have close proximity to the machines, so reducing human interaction and creating a safer working environment is essential. ECONO-PAK has focused on improving safety by facilitating low magazines, which are used to feed the machines with carton material. These low magazines were specifically requested by customers to create a more ergonomic machine and improve carton-forming outputs. 

“One of our customers, an ice-cream producer, was looking to increase the size of their cartons while making sure that the change didn’t introduce any new risks into their packaging operations. Machines with low magazines improve safety by reducing the loading height of the magazine,” Schneider added.

ECONO-PAK and Rockwell Automation have also emphasized ergonomics in the design and operation of their machines. By lowering the magazines, employees no longer need to climb platforms to load in cartons, as they would with a higher-magazine machine. This, along with greater levels of machine automation and digitalization, allows ECONO-PAK to prioritize employee safety while maintaining productivity.

Maintaining Upkeep by Reducing Downtime

Another way that Rockwell Automation has supported ECONO-PAK’s goals is by enhancing machine maintenance capabilities, particularly through remote maintenance. ECONO-PAK’s machines have become "toolless", meaning that machine alterations and changes can be made without the need for conventional tools, such as screwdrivers. This not only creates a safer working environment by reducing the need for direct machine interaction, but also allows for problems to be troubleshooted and solved away from the factory floor.

"Introducing greater remote maintenance capabilities has meant that we can provide our customers with a wide range of benefits, including cost savings, increased efficiency, improved uptime, and enhanced safety by allowing technicians to troubleshoot and repair equipment remotely. These capabilities reduce the need for costly on-site visits and increase productivity and profitability," Schneider said.

Over time, ECONO-PAK intends to advance further in this area by offering predictive maintenance capabilities, which will enable customers to realize significant cost savings by proactively servicing machines and avoiding the risk of downtime.

Better Together

The partnership between ECONO-PAK and Rockwell Automation has been extremely beneficial for both parties. In addition to the specific expertise, skillsets, and knowledge provided by Rockwell Automation, ECONO-PAK has also been able to take advantage of the PartnerNetwork^TM ecosystem. This includes access to a global network of experts and resources, as well as opportunities for collaboration with other leading companies.

At the foundation of the relationship is a close cultural fit and enthusiasm for joint collaboration. According to Sebastian Cruz Euceda, account manager, OEM Region West at Rockwell Automation, “The partnership with ECONO-PAK is one based on mutual trust and transparency throughout the whole company. It’s only by having such a deep level of partnership that we can reach joint success.”

“Our relationship with Rockwell Automation is that of a true partner. It is one that is truly open and collaborative, and it has been this way since the very beginning. This is something very important to us at ECONO-PAK, as our ongoing partnership with Rockwell Automation goes beyond simply fulfilling contractual demands, but to supporting our customers to embrace digitalization and prepare for the future,” Schneider concluded.