Using Guided Format Change to Improve Changeover and Productivity

Long before Covid, we were seeing an increase in the number of packaging SKUs. In 2019, Packaging Digest reported an estimated 42% increase in SKUs in the food and beverage industry.

Since Covid, there has been a further explosion of new packaging sizes, especially in the food and beverage marketplace. Food manufacturers have gotten very creative. Instead of raising prices due to the higher costs of goods, for example, they can reduce the size of product packages while keeping the consumer prices the same.

Many of today’s production machines are not equipped to changeover as quickly and as accurately to meet the demand of the marketplace. Manufacturers now face the challenge of “semi-automating” their existing machines, as opposed to procuring new machines or adding expensive motors to existing machines. One solution is to digitalize change points on existing machines.

Companies are looking to reduce the amount of time and the mistakes that occur when doing product changeovers. Allowing for operator guidance and position measurement can reduce your time and enhance your accuracy of those changeover events. Measurements are then tied to the recipe and the operator becomes the prime mover.

Guided Format Change

There are lots of technologies out there for helping with guided format change, such as automated position measurement, machine position, distance measurement, linear measurement, and digitalized rotary encoders.


As you are likely quite aware, there are often scales, marks, etc., written onto machines that don’t provide the greatest degree of accuracy. Introducing digitalized position and distance sensing can help you reduce time and limit errors during changeovers.

Change Part Identification

The other side of changeover is change part identification. Quite often during this process parts on the machine must be exchanged. Using the wrong change part can result in mistakes, waste, and delays, and can even damage existing machines.

Technologies, such as RFID, can help ensure the correct change part is chosen and added to the machine. During a recipe change, the operator can then validate that all the correct parts are installed before the startup of the next product run.

Guided format change is a cost-effective way to reduce changeover time and increase productivity either by retrofitting your existing machines or even new machines.

IO-Link Makes Improving OEE in Format Change Easier than Ever

One of the primary applications in Packaging, Food & Beverage that is a huge area for improving overall equipment efficiency (OEE) is format change.  Buyers respond well to specialized or individualized packaging, meaning manufacturers need to find ways to implement those format changes and machine builders must make those flexible machines available.

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Today, thanks to IO-Link devices, including master blocks, hubs and linear position sensors, improving OEE on format change is more possible today than ever before. IO-Link offers capabilities that make it ideal for format change. It communicates:

  • Process data (control, cyclical communication of process status)
  • Parameter data (configuration, messaging data with configuration information)
  • Event data (diagnostics, communication from device to master including diagnostics/errors)

What is format change and how does it impact OEE?

Format change is the physical adjustments necessary to make to a machine when the product is altered in some way.  It could be a change in carton size, package size, package design, case size or a number of other modifications to the product or packaging.  The time to adjust the machine itself or the sensors on the machine can take anywhere from 30 minutes to an entire eight- hour shift.

Types of format changes to consider when seeking to improve your OEE:

Guided format change is when the operator is assisted or guided in making the change.  For example, having to move or slide a guide rail into a new position.  IO-Link linear position sensors can help guide the operator, so the position is exact every time. This reduces time by eliminating the need to go back and look at an HMI or cheat sheet to determine if everything is in the right position.

Change parts is when a part needs to be swapped out on the machine for the next production run.  An example of this is when the bag size on a bagger or vertical form fill and seal (VFFS) machine changes and the forming tube needs to be changed.  Having an RFID tag on the forming tube and a RFID reader on the machine allows for easy verification that the correct forming tube was put on the machine and only takes seconds.

Color Change is when the color of a pouch, package or container changes for the next production run like when a yogurt pouch changes color or design while the size and shape remain the same as previous production runs. Smart color photo electric sensors can change the parameters on the photo eye to detect the correct color of the new pouch occurs instantly upon changing the recipe on the machine.

Developing semi-automated or fully automated solutions can improve OEE in regard to format change by helping reduce the time needed to make the change and providing consistent and accurate positioning with the ability to automatically change parameters in the sensor.

Being smart, easy and universal, IO-Link helps simplify format change and provides the ability to change sensor parameters quickly and easily.

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