The packaging industry is undergoing a profound transformation, driven by new market needs and growing consumer expectations. In this context, innovation becomes the key to maintaining competitiveness and meeting global challenges. Ercopac stands as a leader of change, developing solutions that combine cutting-edge technology, environmental care and customization.
Sustainability is no longer an option, but a strategic priority for manufacturing companies, which are increasingly focused on reducing their environmental impact and complying with stringent regulations. With this in mind, Ercopac develops technological solutions that optimize the use of materials and lower energy consumption, supporting customers in achieving their goals of efficiency and environmental responsibility.
- Reducing environmental impact: Ercopac’s wrapping systems are designed to optimize the use of plastic film, contributing to a significant reduction in consumption. In particular, an active patent on the innovative wrapping system allows the film to be distributed more efficiently over the product, lowering plastic consumption by up to 10-20%.
- Energy and maintenance efficiency: The integration of robotics into production processes enables not only lower energy consumption, but also a drastic reduction in mechanical maintenance operations, improving overall line efficiency.
- Focus on Recycling: Ercopac actively promotes the use of recyclable materials in its systems and the adoption of production processes that minimize the generation of waste and scrap, fostering a truly circular approach.
These features translate into a twofold benefit: compliance with environmental regulations and an improvement in the perception of the brand by end customers. As confirmation of its commitment to sustainable practices and responsible production processes, Ercopac has obtained ISO 14001 certification, an international recognition that attests to the effectiveness of the environmental management system adopted by the company.
Smart packaging: automation and artificial intelligence
The concept of smart packaging is revolutionizing the industry by integrating smart technologies to improve the functionality and efficiency of production processes. Ercopac stands out for its use of advanced robotics and artificial intelligence in its systems.
- Column and robotic wrappers: Solutions such as the SPIDER-C e SPIDER-R represent technological excellence, combining several patents and devices that enable greater load stability, production scalability, portability of wrapping recipes, and increased efficiency without production downtime.
- Top cover system: Wrapping systems can be equipped with a top cover system with bottom loading and patented reel-holder changeover that optimizes the production process, enabling continuous and uninterrupted operation.
- Digital interconnection: Ercopac is pursuing development projects to integrate its systems with Industry 4.0 platforms, with the goal of obtaining real-time data and predictive analytics useful for increasingly efficient and intelligent management of operations.
Artificial intelligence not only improves operational efficiency, but also enables rapid response to changes in production needs.
Customization: tailored solutions for every industry
Personalization is one of the pillars of Ercopac’s strategy. Each plant is designed to meet specific customer needs, ensuring maximum operational flexibility.
- Adaptability to sectors: Ercopac’s solutions cover a wide range of sectors, from beverage to food to dairy and tissue, offering systems optimized for each area.
- Modularity of systems: Modular design makes it easy to integrate new features or modify the existing system to accommodate new production needs.
- Operational flexibility: Each plant can handle different sizes, weights and materials, providing a very high level of customization.
This ability to respond specifically to market demands translates into a concrete competitive advantage for Ercopac customers.
Ercopac’s innovative patents
Among the most significant innovations developed by Ercopac are its technology patents, which demonstrate the company’s ongoing commitment to research and development.
Jolly gripper
Multifunctional gripper designed to speed up palletizing cycles with overlapping pallets because, in one move, it places the flap on the last layer, picks up the empty pallet and places the flap on the overlapping pallet. A unique solution that automates and increases the efficiency of the palletizing line while reducing the footprint.
Reel-holder trolley changeover
In top cover systems, automatic reel-holder changeover with bottom loading significantly increases the safety of operators, who do not need scaffolding to perform changeover operations. This system is also equipped with a double trolley that avoids production stops and finished product pallet accumulation, increasing line efficiency and reducing space and costs.
Position of the wrapping head
The reduced distance between the wrapping head and the product during the cycle is a patented expedient that allows maximum precision in cutting and welding operations, as well as a relevant speeding up of the diagonals that provide excellent stability to the load.
Fifth axis of the wrapping head
Thanks to the addition of the fifth axis of the wrapping head in our column wrappers SPIDER-C, they are able to exactly replicate the movements of SPIDER-R robotic systems. This means that different wrappers can be installed depending on production speeds and space requirements, and can then use the same wrapping recipes on all machines, ensuring equal technical stability and quality characteristics.
In-line wrapping test
The ability to test the quality of the wrapped load directly in-line as it exits the wrapping process has multiple advantages, including reduced costs associated with testing at external laboratories, real-time monitoring not only of the wrapping but also of all previous operations, and a major reduction in waste and returns.
These patents represent Ercopac’s technical excellence and its contribution to the advancement of the industry.
Continuous innovation for customer success
For Ercopac, innovating means anticipating market needs and offering solutions that create value for customers. Through an approach focused on research and development, the company aims to transform the future of packaging into a more efficient, sustainable and technologically advanced reality.
With a unique combination of patented technology, customization, and sustainability, Ercopac is the ideal partner for companies that want to meet the challenges of the global market with innovative, cutting-edge tools.
Innovation in packaging is not just a trend, but a necessity to compete in an ever-changing market. With Ercopac, companies can count on a reliable partner that can offer scalable and sustainable solutions that meet production needs, improve efficiency and reduce environmental impact.
Innovation in packaging:
What are the main current trends in packaging innovation?
Major trends include:
Sustainability: Using recycled, recyclable, biodegradable or compostable materials, reducing waste, optimizing packaging life cycle.
Smart packaging: Integration of smart technologies such as QR code, NFC, RFID, sensors, augmented reality for traceability, consumer interaction, cold chain monitoring, etc.
Personalization: Offer customized packaging to create a stronger connection with the consumer and address specific needs (e.g., limited editions, interactive packaging).
Functional and minimalist design: Create packaging that is not only aesthetically pleasing, but also easy to use, transport, and dispose of.
E-commerce friendly packaging: Develop packaging that is resistant to the impacts and stresses of e-commerce shipping, while optimizing size and weight to reduce shipping costs.
Why is innovation so important in the packaging industry today?
Innovation is critical for several reasons:
– Responding to growing consumer and regulatory demands for sustainability.
– Improving supply chain efficiency and reducing costs.
– Differentiating from competitors and creating added brand value.
– Enhancing the consumer experience and creating a stronger bond.
– Adapting to new sales channels, such as e-commerce.
What are the main challenges companies face when trying to innovate in packaging?
Challenges include:
– Cost of research and development and implementation of new technologies.
– Difficulty in finding sustainable materials that meet all performance requirements.
– Need to adapt existing production lines to new packaging technologies.
– Ensure safety and regulatory compliance.
– Effectively communicate the benefits of new packaging solutions to consumers.
How do you measure the success of a packaging innovation?
Success can be measured by several indicators:
– Environmental impact (e.g., carbon footprint reduction, waste reduction).
– Economic performance (e.g., reduced production costs, increased sales).
– Customer satisfaction (e.g., positive feedback, increased brand loyalty).
– Supply chain efficiency (e.g., reduced damage during transportation, optimized storage space).
– Industry recognition and awards.
What is the role of consumers in packaging innovation?
Consumers play a crucial role, as their needs and preferences drive market trends. Companies must listen to consumer feedback and develop packaging solutions that meet their expectations in terms of sustainability, functionality, aesthetics, and convenience.
Sustainability in packaging:
What exactly is meant by “sustainable packaging”?
Sustainable packaging is packaging that minimizes environmental impact throughout its life cycle, from production to disposal. This includes using recycled, recyclable, biodegradable or compostable materials, reducing consumption of natural resources, optimizing packaging weight and volume, and reducing waste.
What are the most sustainable packaging materials available today?
– Recycled paper and cardboard.
– Bioplastics (e.g., PLA, PHA).
– Compostable materials.
– Natural fiber-based materials (e.g., cellulose, bamboo).
– Recycled plastic (PCR).
How can the environmental impact of packaging be measured?
Environmental impact can be measured through several methodologies:
Life Cycle Analysis (LCA): Assesses the environmental impact of a product or packaging throughout its entire life cycle, from raw material production to disposal.
Carbon Footprint: Measures the amount of greenhouse gases emitted during the life cycle of a product or packaging.
Ecodesign: Design approach that aims to minimize the environmental impact of a product or packaging from the design stage.
What are the most important regulations and certifications regarding sustainable packaging?
Some examples include:
– European Packaging and Packaging Waste Directive (94/62/EC).
– ISO 14000 standard for environmental management.
– Compostability certifications (e.g., EN 13432).
– Recyclability certifications.
How do you reconcile the need for protective packaging with the need for sustainable packaging?
It can be reconciled through the use of innovative materials that offer both protection and sustainability, optimizing packaging design to reduce material consumption, and choosing appropriate end-of-life solutions (e.g., recycling, composting).
What are the costs and economic benefits of sustainable packaging?
The upfront costs of implementing sustainable packaging solutions may be higher, but in the long run they can lead to savings through reduced waste, optimized resource use, and improved brand image.
Smart packaging
What is “smart packaging” and what technologies does it include?
Smart packaging integrates technologies that enable packaging to interact with its surroundings, the product it contains, or the consumer.
Some technologies include:
– QR code and barcode.
– NFC (Near Field Communication).
– RFID (Radio-Frequency Identification).
– Sensors (e.g., temperature, humidity, pressure).
– Augmented Reality (AR).
– Smart Inks.
What are the practical applications of smart packaging in different sectors?
Examples:
– Traceability and anti-counterfeiting (food, pharmaceutical).
– Cold chain monitoring (food, pharmaceutical).
– Consumer interaction (marketing, product information).
– Inventory and logistics management.
– Improving product shelf-life.
What are the benefits of smart packaging for companies and consumers?
Business benefits:
– Improved traceability and supply chain management.
– Protection from counterfeiting.
– Collection of consumer data.
– Improved marketing and communication.
Benefits for consumers:
– Detailed product information.
– Interactive experiences.
– Increased security and transparency.
What are the challenges associated with implementing smart packaging (e.g., cost, security, privacy)?
Challenges include:
– Technology implementation costs.
– Integration with existing systems.
– Data security and consumer privacy.
– Technology standardization.
What is the role of artificial intelligence and robotics in smart packaging?
AI and robotics are transforming the packaging industry in several ways:
IA:
Data analysis: AI can analyze data collected from sensors and tracking devices to optimize the supply chain, predict demand, customize offerings, and improve the consumer experience.
Quality control: AI can be used for automated quality control, detecting defects and anomalies in packaging more efficiently than traditional methods.
Predictive maintenance: AI can predict when packaging machines need maintenance, reducing downtime and optimizing production efficiency.
Robotics:
Packaging automation: Robots can automate packing and packaging operations, increasing speed and accuracy.
Palletizing and material handling: Robots can be used for palletizing, handling and storage of materials, optimizing logistics and reducing costs.
Packaging customization: Robots can be used to apply custom labels, print variable messages, or flexibly assemble complex packages.
How do smart packaging technologies integrate with Industry 4.0 systems?
Smart packaging is a key element of Industry 4.0, as it enables the collection and exchange of data throughout the supply chain.
Integration occurs through:
- Connectivity: Smart packaging devices (sensors, RFID tags, etc.) are connected to the Internet via IoT (Internet of Things) networks, enabling data transmission to cloud platforms.
- Data management platforms: Industry 4.0 platforms collect and analyze data from smart packaging, providing useful information to optimize production, logistics, marketing, and product lifecycle management.
Integration with ERP and MES systems: Smart packaging data can be integrated with ERP (Enterprise Resource Planning) and MES (Manufacturing Execution System) systems for integrated management of enterprise resources and production processes.
What specific solutions does Ercopac offer for sustainability, technology and packaging customization?
Ercopac offers a range of machines e innovative and patented for the world ofpackaging automation. The portfolio includes end-of-line solutions dedicated to depalletizing, labeling, wrapping, palletizing and handling, with robotic and traditional solutions.
The solutions offered accompany customers throughout the entire equipment life cycle, from design to revamping. This includes supply, installation, commissioning and maintenance. Ercopac continuously strives to provide customized solutions developed to meet specific needs.
What are the specific sectors in which Ercopac operates and what solutions does it offer for each sector?
Ercopac ‘s solutions are versatile and applicable in various industries, including Beverage, Food and Tissue. The range of robotic bundlers and column wrappers, the depalletizers and the labelers are designed to meet different production needs and different product and packaging types. The range of robotic palletizers instead includes two different grippers for layer configuration, one specifically for Beverage and one specifically for Tissue.
Regarding row palletizing, Ercopac offers a variety of highly customizable motorized and pneumatic grippers, for example, the bottle gripper, case gripper, tube gripper, and half-layer gripper. Finally, the empty pallet control systems are designed to be extremely flexible and easily adaptable to a wide variety of production requirements.
What are the specific advantages of choosing Ercopac as your packaging innovation partner?
Ercopac ‘s products are the result of constant research and development, and blend technology and high performance to offer solutions that optimize production processes. A major advantage, resulting from more than 20 years of experience of Ercopac engineers and theuse of robotics, is theadoption of proprietary, customized software for the operation of all systems.
Added to this is the ability to take advantage of fast response times: within 24 hours domestically and 48 hours abroad.
Flexibility and speed also characterize the fabrication and installation of systems for Ercopac customers.
How can I contact Ercopac for more information or personalized advice?
- Generic contact: info@ercopac.com
- Business contact: marketing@ercopac.com
- Request technical info: form on the pages dedicated to each product
- Phone: 0522 988373
