The New, Noteworthy and Game-Changing: Product Launches at PACK EXPO 2024

PACK EXPO International runs biennially, making it a must-attend trade fair if you’re going to keep up with the latest developments in packaging machinery; materials; packages and containers; automation and robotics; digital printing and labeling; and supply chain solutions.

Whether yours is a growing brand looking to scale up and expand operations, or you’re a contract services provider looking for ways to differentiate, this event offers fresh perspective on how comparable companies are advancing their growth strategies and overcoming automation, innovation and sustainability challenges in manufacturing and packaging.

According to Contract Packaging & Manufacturing: Drivers of Machinery Investments, a report published by the show producer, PMMI (The Association for Packaging and Processing Technologies), 87% of contract manufacturing firms interviewed plan to install new equipment in the next three years to increase flexibility (78%), expedite changeover (53%) and simplify machine operation (46%).

The most popular machinery additions, according to PMMI’s report, are in palletizing (40%), case/tray handling (35%), label/decorating/coding (32%), form-fill-seal (31%), cartoning (30%), filling/dosing (26%), bottling line (25%) and wrapping/bundling (22%).

The list below is a mere sampling of new and innovative technological advancements that attendees were exposed to this year. Feel free to find out much more about what the packaging and processing industry has to offer by navigating here.

The Smallest Fin Sealing and Zipper Crushing System

Global demand for lightweight, portable, durable and convenient packaging is good news for ultrasonic welding equipment manufacturers such as Rinco Ultrasonics. The company launched two new products at PACK EXPO, namely the Micro-35 packaging actuator and the FPA4500EM servo-driven pouch sealer.

Rinco’s new Micro-35 Actuator is a welding unit that operates on a 35-kHz frequency and was designed for continuous fin sealing and zipper crushing applications for the packaging industry.

Ultrasonic sealing or welding is a preferred sealing method that operates on the principle of converting electrical energy into high-frequency mechanical vibrations, typically in the ultrasonic range (around 20 kHz or higher). The heat is generated only inside of the materials to be welded. In addition to forming strong, airtight and watertight bonds, it offers speed, precision and sanitary sealing, making it ideal for assembling products like medical devices, automotive components and consumer electronics. The lightweight actuator system makes it viable for continuous movement zipper crushing applications where the actuator must move with the film.

Rinco’s press release characterized ultrasonic welding as a more sustainable process when compared to traditional methods and has the capability of sealing recycled and bio-based films as well as many paper-based materials. Thermal sealing processes are blind and often affected by ambient conditions and are unable to confirm seal quality. Rinco noted that intelligent ultrasonic systems provide a high level of process data, offering insight into the sealing process.

Rinco Ultrasonics’ new Micro-35 actuator is the smallest fin sealing and zipper crushing system in the industry.

A Servo-Driven Pouch Sealer

Rinco’s FPA4500EM servo-driven pouch sealer can dynamically manipulate key parameters such as vibratory amplitude, weld force and stroke velocity during the weld cycle, ensuring the best possible weld strength and the fastest possible cycle time. According to Rinco, eliminating the use of compressed air to develop seal force means the new servo-driven welder significantly reduces energy consumption. The servo system monitors the force and position of the sealing tools and can detect folded and missing pouches, noted the company’s press release.

In the ultrasonic process, the high-frequency vibrations generate frictional heat within the materials being sealed. A melt is created almost instantaneously, which offers productivity benefits where thicker films are being used. Furthermore, data available from the ultrasonic generator provides process control benefits that are not available with thermal sealing, stated the company.

By eliminating the use of compressed air to develop seal force, Rinco Ultrasonics’ FPA4500EM servo-driven pouch sealer significantly reduces energy consumption.By eliminating the use of compressed air to develop seal force, Rinco Ultrasonics’ FPA4500EM servo-driven pouch sealer significantly reduces energy consumption.

A Floor-to-Cloud Approach to Energy Management

Emerson’s extensive product line was on full display to enable smarter packaging lines and more efficient processes. Emerson experts demonstrated ways to unleash trapped data and link up traditionally passed-over machinery and equipment. The product selection highlighted how to accelerate net zero progress, raise overall equipment effectiveness (OEE) asset by asset, and systems that empower staff with data to drive continuous improvement. For example, operators can gain visibility through the Energy Manager, a pre-engineered hardware and software solution that simplifies asset energy monitoring in real time. Dashboards display asset-specific consumption, associated costs and carbon dioxide (CO2) emissions for up to 10 end points (expandable to 50 with a license).

Combined with the Emerson Compressed Air Manager, the Energy Manager presents a streamlined view of energy costs and compressed air usage across a packaging line, factory and site. To this end, Emerson now also offers a high flow model of an advanced sensor that propels compressed air monitoring beyond individual machines to benefit larger air lines and systems. The Aventics Series AF2 Flow Sensors brings expanded capabilities to compressed air consumption and energy efficiency, allowing users to optimize across an entire packaging facility and improve overall plant sustainability.

By monitoring air consumption in pneumatic systems, AVENTICS Series AF2 Flow Sensors enable rapid intervention if leaks occur.

Digital Imaging Solutions Collaborate with Robotic Bagging Solutions

Canon USA demonstrated an AI-based robotic perception and pick-and-place software solution developed by Osaro, a San Francisco-based robotic automation integrator. Osaro’s Robotic Bagging System is fitted with Canon’s optical-encoder-based, low-cost force-torque sensor, which measures the magnitude and direction of load along three axes and rotational forces. When attached to a robotic arm, a force sensor helps the arm sense the strength needed to handle objects.

Powered by Osaro’s advanced AI and machine-learning algorithms, Osaro SightWorks enables the automatic addition of thousands of SKUs. The system features Canon’s proprietary optical encoder technology, including a force torque sensor that measures three-quarters of an inch (in thickness) and weighs .55 lb. A digital mechanism works to provide high precision levels, and the Canon Force Torque Sensor Application Software connects users to a personal computer. No coding needed.

Osaro has unveiled a significant advancement in its Osaro SightWorks perception platform with the release of Osaro AutoModel, which accelerates the introduction of new SKUs. Osaro’s experts note that the system monitors performance, identifies when an improvement can be made, retrains a model, tests the new model and deploys it without the robot ever stopping. The new advanced AI perception algorithms are well suited to high-volume piece-picking and kitting applications and customers will benefit from real-time AI model updates and ongoing performance optimization, they said.

Osaro’s AI-powered software streamlines new SKU introduction and provides greater flexibility and efficiency in kitting, piece-picking and autobagging.

Remote Monitoring and Error Recovery for Industrial Robotics

Seattle-based Olis Robotics specializes in remote control and error-recovery systems for industrial robots. Specifically, the technology focuses on video-based diagnostics and telemetry. Their latest collaboration is with Hamrick Packaging Systems, a packaging equipment OEM, which integrated the Olis remote monitoring, control and troubleshooting system directly into the HMI panel. Olis monitors and diagnoses all PLC-controlled hardware in the cell (not just the robot arm). Hamrick’s display at Pack Expo featured Olis in a robotic bottle packing application, offering customers the ability to restart production faster, reduce troubleshooting and downtime costs by up to 90%, while gaining access to expert support quickly. After a system failure, operators can use Olis to run a tool inspection routine and perform remote error recovery, allowing the robot to resume its cycle and get back to work. Olis was also displayed at the Universal Robots and Kawasaki booths.

In a new collaboration with Hamrick Packaging Systems, a packaging equipment OEM, Olis Robotics integrated its Olis remote support, diagnostics and error recovery software directly into Hamrick’s HMI panel.

Multi-Tech Palletizing and Conveying

Bosch Rexroth demonstrated its complete factory automation solutions for CPG manufacturing. A multi-tech collaborative palletizing demo, it is built on Bosch Rexroth’s aluminum structural framing, consisting of a VarioFlow plus conveyor system that delivers high accuracy with unprecedented speed, combined with a Kassow 7-axes collaborative robot. The modular VarioFlow plus plastic chain conveyor is a high-performance versatile plastic chain conveyor system with components that are easy to assemble in both horizontal and vertical configurations. In addition, Linear Motor Modules feature a zero-backlash direct drive. The LMMs come ready-to-install, with axes are available in sizes 140 mm, 180 mm and 220 mm.

Bosch Rexroth's featured a multi-tech palletizing demo, highlighting different components—from conveyors and control systems to linear motor modules and a multi-axis handling system.

Cross-Industry Automation Innovations

Coesia brought an international flair with its suite of advanced technologies, production solutions and automation representing 10 companies, 17 solutions and nine product launches at its 2,000 sq. ft. booth. Collaborating with Beckhoff, experts from R.A Jones (a Coesia company) presented on the Pack Expo Innovation Stage on the subject of “Cabinet-Free Machine Designs” and their impact on modern manufacturing.

At the booth, key solutions targeting the U.S. market focused on flexibility, reduced cost of ownership and operational excellence. One example is an advanced digital printing solution, blisterjet agile from Hapa, a Coesia company, which enables late-stage customization for blister packaging. With CMYK or spot color capabilities and integrated vision inspection, it improves flexibility while ensuring consistent print quality.

Hapa’s blisterjet agile enables late-stage customization for blister packaging.

In the food area of the booth, demonstrations included a selection of Flow Packing, Chub Packing, and Robotics solutions. For example, the Norden NM 702 Tube Filler is a high-efficiency tube-filling machine that can handle various sustainable materials, such as mono-materials and paper-based tubes, making it ideal for personal care and pharma applications.