IT in Manufacturing


Automation of a thermoforming machine for recyclable packaging

Technews Industry Guide: Sustainable Manufacturing 2023 IT in Manufacturing

Thermoforming is the most common method for producing trays, dishes and packaging from plastics at low cost; however, many consumers take a critical view when it comes to using plastic as a packaging material. Renewable cellulose is an excellent alternative, which is why Hamer has joined forces with Beckhoff to develop a thermoforming machine for

water-based cellulose pulp.

When asked what prompted Hamer to embark on such an ambitious project, Joan Ferrer from the electrical and software department says, “Concern for the environment led us to develop a technology for fully recyclable and environmentally friendly cellulose packaging. The special feature of the technology is the way the cellulose is dried out by means of a specific combination of pressure and temperature. This creates dimensionally stable packaging with clearly defined contours that can be adapted to the dimensions and shape of the item it contains, making it suitable for a wide range of products. With the HP96 thermoforming machine for pulp, we can now offer our customers a sustainable alternative to conventional plastic packaging for the first time.”

The process is entirely environmentally friendly, both in the extraction of the raw material and in the way it is subsequently recycled. The packaging material is biodegradable and 100% compostable. The fact that cellulose does not become electrostatically charged means it can be used to package electronics safely too.

The Hamer HP96 also offers a host of advantages in terms of technology and productivity. Running four cycles per minute, it outperforms comparable machines on the market by more than double, with a forming area of 900 x 600 mm and a forming depth of up to 100 mm. The machine can process up to 300 g of cellulose per cycle, equating to around 72 kg per hour, or 576 kg per shift.

Extensive vertical integration plus an open automation platform

Hamer can look back on four decades of experience in the packaging industry. Boasting a high level of vertical integration, the company maintains firm control over all processes, including design and automation technology. The latest evidence of this can be found in wet fibre thermoforming, which Hamer has developed together with Beckhoff. “The development project was really challenging, technically speaking,” recalls Octavi Marti from the sales team at Beckhoff’s Barcelona branch. The business relationship between the two companies was very close throughout the project, with Beckhoff’s comprehensive automation portfolio attracting the interest of the Hamer team.

Wet fibre thermoforming for sustainable packaging

The process starts with preparing the fibres, which involves mixing the basic materials with water to achieve the required consistency. A vacuum absorption process then transports the cellulose pulp from the main tank into the thermoforming machine. This is where high-quality 3D-moulded products are created in the thermoforming mould through sophisticated control of the temperature, pressure, pressing time, vacuum, and hot drying. The result of this process is packaging with a high level of mechanical strength, along with an ideal surface finish and shape. Any remaining production materials flow straight back into the production cycle via closed conveyor and water circuits to cut down on both material consumption and disposal costs.

The anodised housing and high IP69K protection rating of the servomotors in the AM8700 series offer ideal protection against the large amounts of steam and water that are produced during the process. What’s more, the One Cable Technology (OCT) of the servomotors also cuts down on wiring work. Other key elements for the development manager include the IP65-protected CP3916 control panel and TwinCAT HMI (TF2000). “Both of these allow intuitive control of all processes performed with the equipment, while also increasing the efficiency and safety of the thermoforming machine,” notes Ferrer. The visualisation is entirely based on HTML5 and is therefore platform independent, making Hamer’s HMI futureproof, since the machines can be operated from any PC or other mobile device. Implementing TwinCAT even makes it possible to extract machine data in a variety of different ways, object-oriented programming makes it easier to reuse code, and Git version management software is also incredibly beneficial.

This project is an important milestone for Hamer and demonstrates how innovation and collaboration can lead to unique and effective solutions. “I am confident that our collaboration will produce more innovative and efficient packaging solutions going forward,” says Ferrer. “In fact, we have already identified the Beckhoff technology that we have our sights set on next, namely TwinCAT Vision, TwinCAT Analytics, and TwinCAT Cloud Engineering.”


Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Sustainable energy management
Siemens South Africa IT in Manufacturing
Utilising its innovative ONE approach technology, Siemens provides complete transparency on resource consumption and offers data-driven optimisation recommendations for sustainable energy management.

Read more...
Paving the way for a carbon-neutral future in South Africa
IT in Manufacturing
At ABB Electrification, we believe the infrastructure of the future must do more than support daily operations, it must anticipate them. We are committed to building intelligent systems that connect and optimise infrastructure across sectors.

Read more...
Africa’s hidden AI advantage
IT in Manufacturing
Through my work implementing AI systems across three continents, I’ve become convinced that Africa’s unique context demands urgent AI adoption. Successful implementation requires local expertise to understand resource constraints as design parameters to create the innovations that make technology truly work under real-world conditions.

Read more...
Siemens Xcelerator empowers space-tech pioneer, Skyroot Aerospace
Siemens South Africa IT in Manufacturing
Siemens Digital Industries Software has announced that Skyroot Aerospace, a leading private space launch service company in India, has adopted Polarion software from the Siemens Xcelerator portfolio to digitally transform its software development processes and enhance efficiency as it aims to accelerate access to space for its customers worldwide.

Read more...
Water is running out, is your ESG strategy ready?
IT in Manufacturing
Water is one of the most critical yet undervalued resources in modern business. Water stewardship asks businesses to understand their water footprint across the entire value chain and to engage with others who share the same water resources.

Read more...
Cybersecurity in 2025: Six trends to watch
Rockwell Automation IT in Manufacturing
Rockwell Automation’s 10th State of Smart Manufacturing report finds that cybersecurity risks are a major, ever-present obstacle, and are now the third-largest impediment to growth in the next 12 months.

Read more...
The state of the smart buildings market in 2025
IT in Manufacturing
Smart buildings are entering a transformative phase, driven by sustainability goals, technological innovation and evolving user expectations. According to ABI Research’s latest whitepaper, the sector is undergoing a strategic overhaul across key areas like retrofitting, energy efficiency, data-driven operations and smart campus development.

Read more...
Digital twin for Bavaria’s National Theatre
Siemens South Africa IT in Manufacturing
Siemens and the Bavarian State Opera are digitalising the acoustics in Bavaria’s National Theatre in Munich, Germany. The result is a digital twin that simulates sound effects, orchestral setups and venue configurations in a realistic 3D acoustic model so that musicians, the director and conductors can assess a concert hall’s acoustics even before the first rehearsal.

Read more...
How AI can help solve South Africa’s water crisis
IT in Manufacturing
Climate change, ageing infrastructure, pollution and unequal access are putting intense pressure on the country’s water systems. A powerful question arises: “Can artificial intelligence help us change course?”

Read more...
Backup has evolved, but has your strategy?
IT in Manufacturing
With cyber threats rising and compliance standards tightening, South African organisations are under growing pressure to revisit their data protection strategies. The era of treating backups as a box-ticking exercise is over.

Read more...









While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements and company contact details are published as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.




© Technews Publishing (Pty) Ltd | All Rights Reserved