Automated Product Changeover with LineXpress

Changing over lines in record time

Broad range of products and small single batches often push many lines to their economic limit due to complex changeover processes.

With LineXpress, you can maximise the efficient use of your production time. The solution automates the changeover process as a whole as well as the control of the material flow. Essential processes can therefore run quickly, defined and repeatable.

At a glance

Automation and coordination of the changeover process on one line
Reduced product changeovers to up to 10 minutes
Reduced handling parts changeover to up to 30 minutes
Minimises the operating effort: Manual tasks are reduced by 80 percent
Increases the line efficiency by up to 20 percent
Can be used on lines with ErgoBloc L and Contiform Bloc

* Exact line-wide changeover times must be assessed as part of the individual customer project.

Brochure Krones LineXpress

1.95 MB, .pdf

How LineXpress works

Changeover of complete lines with few operators

Automated format changeover for individual line sections, for example:
- Mould changeover with robot on the stretch blow moulder
- Adjustment of the bottle format on the filler
- Change of pack size and type on the packer
Central coordination of the order changeover via the Line Management software:
- Automatic parameterisation of the machines
- Flying batch changes: Successive orders are produced in parallel with a controlled gap, the line does not have to be completely emptied
- Additional operator guidance
Optimisation of the material flow: "Last bottle, last product, last preform, last cap"

Blocks for LineXpress

Available for lines with Contiform Bloc and ErgoBloc L

How LineXpress centrally controls all your process steps

Functions

Order management with central selection of machines, routes and changeover options (e.g. final conditions tank/quantity)
Automatic parameterisation of all machines (e.g. type/program) as well as the standard printer/coding devices
Automatic start-up, emptying and changing over of all machines incl. the control of the UnitXpress quick-change functions
Automatic planning of intermediate flushing or CIP and display of the desired CIP program based on a cleaning matrix
Flying batch changeover with automatic start of the following batch and controlled gap between the orders in the line

LineXpress – your access to Line Management

User-friendliness at a new level

Clear and straightforward visualisation system: Order progress, material and changeover information to all Connected HMIs and in Line Management (browser-based, access via the Line Management Panel and with every end device)
Less task required from the operators during changeover (no pre-parameterisation at every Connected HMI necessary)
Operator guidance informs about manual order changeover processes
Including three-months operations consulting for assisting the start phase (remote)

Providing support in all areas of production

Benefits to you

Line availability

Use your line via reduced changeover times, batch summary and flying order changes optimally and gain 20 percent or more efficiency during the main season and up to 40 percent during off season.

Minimum personnel required

Significantly reduce your manpower requirements: Thanks to largely automated changeover processes, the changeover time for format changeover is reduced by to up to 30 minutes, repeatable and with just 2.5 operators per line.

Quality assurance

Automation and system-supported operation keep the potential for errors and downtimes to a minimum and raise quality and efficiency to the highest level.

More flexible planning

Short changeover times enable smaller batches and frequent article changeovers. This means you do not need large storage capacities and can realise just-in-time production depending on the demand.

Variant variety

Produce a wide range of packaging variants (SKUs) without losing efficiency due to long changeover times.

Future-proof and customisable

LineXpress is supplied with the modular Line Management software and can be easily expanded to include material management and integrated into your existing IT landscape.