Suppose you run a frozen pizza assembly line. What would happen if your production equipment only deposited sauce on half the pizza, or covered one slice with pepperoni but not the others? Customers would certainly be less than pleased; that’s for sure.
This is why having an orientation system is a must for food production lines. In this guide, you’ll learn how an orientation system works, the benefits of implementing one, and how to address challenges with your orientation system.
Components of an Orientation System
Orientation systems are complex machinery that includes sensors, actuators, and control systems. If you’re unfamiliar with robotics, you’re probably not sure what these terms mean. We’ll break it down for you in plain English below.
Sensor Technology
You have eyes, ears, and a nose to help you sense things in your environment, but a machine doesn’t have these human traits (at least, not yet). That’s why they must rely on sensors to help them detect things, such as motion, sound, temperature, light, and pressure.
There are a few different kinds of sensors. Vision sensors capture and process images as products pass through conveyor systems, while force sensors measure pressure. Touch sensors, as you might expect, measure physical contact.
Actuator Types and Mechanisms
How do robots act on the information they receive from sensors? It’s all thanks to the robot’s actuator. Actuators convert mechanical or electrical signals into motion.
As with sensors, actuators come in several varieties. Servos allow precise control over robotic limbs, and motors provide linear or rotational movement. Pneumatic and hydraulic actuators rely on gasses or fluids to create force.
Control System
If a robot’s sensors are its eyes and ears, its control system is the brain. Essentially, the control system tells the robot what to do.
You can opt for either a closed-loop or open-loop control system. Closed-loop systems rely on sensor feedback to adjust a robot’s movements in real time, making them very precise. Open-loop systems perform predetermined actions based on inputs.
Feedback Mechanisms and System Integration
Feedback mechanisms operate on a sort of “if-then” programming. These mechanisms specify a set point for a control system loop, and then verify that the robot has made the correct movement.
Orientation System Operation
So, how does an orientation system work? Here’s the basic gist of the process.
Product Detection and Data Acquisition
As objects move down the assembly line, the orientation system scans them, allowing the system to identify the objects. For example, the system might use vision sensors to determine the size of a package or ingredient as it passes through the feeding systems.
Decision-Making and Control Algorithms
Once the system has identified the object, it has to decide what to do with it. That’s where the positional control system comes in. The control system enables the orientation system to make decisions about passing objects on the fly.
Actuator Activation and Product Reorientation
If an object is in the wrong position, the part orientation system activates its actuators to correct the issue and put the object in the proper place.
Verification and Correction Processes
Next, the orientation system verifies that the object was moved into the correct position. If repositioning fails, the system will alert an operator.
Benefits of Implementing an Orientation System
Why consider an orientation system for your food production line? Check out these enticing benefits.
Increased Production Efficiency
Let’s face it; moving food products and packaging by hand can be slow. Time is money, and if you want big profits, you can’t go without an orientation system. These systems keep your production line humming along by improving automation efficiency and reducing orientation errors that would otherwise slow your operation to a halt.
Reduced Labor Costs
Hiring workers to run your production line can be prohibitively expensive, especially if you’re just starting out or are a small business owner. An orientation system reduces the need to hire more staff. It can do the job of several employees in a fraction of the time.
Compare the cost of an orientation system to the amount you pay employees, and you’ll quickly see how it’s a good investment.
Improved Product Quality
Imagine that a peanut ended up in a product that was supposed to be allergen-free, or a chunk of packaging got mixed in with a bag of potato chips. Such problems can lead to everything from customer annoyance to costly lawsuits.
An orientation system reduces the risks of issues like these. You can’t be there to stop every little mistake from happening on your line, so why not let an orientation system do it for you?
Enhanced Safety
Orienting products by hand can sometimes be a dangerous affair. Line workers may have to reach into machinery, putting them at risk of injury. Should an employee become injured, expect your workers’ compensation premiums to increase. Orientation systems are robotic, so they can’t get injured like humans can.
Orientation System Challenges and Solutions
Orientation systems have many perks, but also some challenges to be aware of.
Product Variations
Food products and packaging come in all different shapes and sizes, and some orientation systems will be better at detecting certain objects than others. You’ll need to buy the system that best suits your production line’s needs.
Line Speed and Throughput Requirements
Some orientation systems are incredibly accurate but a bit slow, while others work quickly, allowing for more inaccuracies. The goal is to choose a system that offers a good balance between the two.
You can choose from rotary and inline indexing systems. Rotary systems are designed to operate continuously, in turn increasing your throughput and ROI. If high speeds are most important to you, opt for a rotary system.
Inline indexing systems provide lower speeds and higher accuracy. They’re ideal for lines that run 120 items or less per minute.
System Reliability and Maintenance
When you buy an orientation system, you want it to stand the test of time. Be sure to purchase your system from a manufacturer known for reliability. Your system should also be easy to maintain and repair.
Optimization Techniques for Efficiency
To improve the efficiency of your orientation system:
- Analyze the needs of your production line to help you choose the right type of system.
- Calibrate all equipment before using it for the first time.
- Identify bottlenecks in the line, such as supply delays and equipment resting time.
- Determine your KPIs, such as throughput and cycle time.
- Implement a data collection and analytics system to help you accurately measure metrics.
- Choose lean manufacturing processes, such as value stream mapping, which enables you to identify all steps in your process and eliminate any that don’t add value.
- Regularly inspect your orientation system and other equipment to ensure it’s operating at peak efficiency.
Trends and Future Developments
Orientation systems have come a long way in the past few decades, and new advancements continue to make these workhorses more efficient than ever before.
Emerging Technologies
Machine learning (ML) and artificial intelligence (AI) are the next big thing in orientation system technology. One study found that using the right mix of AI technologies can slash your conversion costs by up to 20%.
The Internet of Things (IoT) is another technology worth paying attention to. IoT allows you to integrate your orientation system with other equipment on your line. You can even use this technology to have alerts sent from your system straight to your phone or smartwatch.
Advancements in Sensor and Actuator Technology
Sensors and actuators are constantly improving, too. Thanks to these improvements, sensors will be able to detect objects more accurately and with greater speed.
Many production lines are choosing to replace hydraulic and pneumatic actuators with electric ones. Electric actuators don’t leak like these other types of actuators can. Additionally, they have a lower weight, smaller footprint, improved force, and faster response time.
Sustainable Orientation Solutions
Do you care about your carbon footprint? Your customers certainly do. One 2023 study found that up to 78% of consumers would prefer to do business with an eco-friendly brand.
Switching to a sustainable orientation system is a smart move for both your brand image and your bottom line. Luckily, you have plenty of choices when it comes to environmentally friendly machinery.
We’ve already mentioned the benefits of electric actuators, but there’s more: These systems don’t rely on unsustainable fossil fuels like other types of actuators do, nor do they pollute the environment with toxic gasses and waste.
You can further improve sustainability by:
- Choosing food packaging made with sustainable materials, such as paper instead of plastic
- Working only with suppliers committed to eco-friendliness
- Reducing your consumption of fuel, water, and raw materials
- Developing and following a policy for proper waste disposal
Trust TDI Packsys for Your Production Line Optimization
Now that you’ve learned the answer to, “How does an orientation system work?” why not check out our packaging automation and inspection system solutions? TDI Packsys is a top provider of orientation, rejection, and separation systems, food metal detectors, color sorters, and more.
To learn more about our orientation systems or our other offerings, contact TDI Packsys at (877) 834-6750.
