Digital transformation is without a doubt the key to efficient, competitive production. But the term covers a wide range of possible initiatives, many of which cannot be implemented ad hoc because they tie up considerable human and financial resources. Add to this the risk that a flawed transition will not only lead to production delays but also cause quality problems and waste. Furthermore, inefficient use of resources significantly increases operating costs. In high-speed packaging technology production, these are factors that need to be avoided at all costs. The LEIBINGER Connect digital control station is a prime example of how simple, precisely targeted steps can have a big impact.
Packaging machines are among the fastest systems in industrial manufacturing. Cycle times of a few hundred milliseconds are hard-fought. But no matter how powerful a machine may be, it remains part of a finely tuned process chain: packaging, coding and marking, documenting and tracing. Only when all these processes are seamlessly integrated can the line achieve the productivity that is needed in today’s world.
Coding and marking as an integral part of the whole
Product coding and marking is a perfect example of how many factors interact. It typically takes place at the end of the line and, at first glance, seems like a minor detail. In reality, however, it is critical for traceability, delivery and regulatory compliance. Here, too, the technology has to be available around the clock – reliably, without long start-up times, changeovers, malfunctions or maintenance marathons. Robust mechanics and reliable, high-quality marking performance ensure operation when every second counts.
Digital relief where people are in short supply
This is compounded by the shortage of skilled workers. In maintenance or shift work in particular, there is often not enough time to keep an eye on several lines simultaneously. Those who are responsible for multiple packaging lines have to juggle between different halls, search for the causes of malfunctions, check consumable material levels and coordinate maintenance. A central overview of coding and marking systems, ideally integrated into the ERP, saves time and reduces the risk of incorrect responses. LEIBINGER Connect was developed specifically for this purpose. The control station provides networked monitoring of every connected printer unit at a glance, thereby maximising printer efficiency.
A glance at one central system makes all the difference
How does this all look in practice? Here is an example. A shift supervisor is responsible for several lines with LEIBINGER marking systems. Instead of working their way through individual messages or manual checks, they can see at a glance which printer is running, which is paused, where material is running low or maintenance is due. The shift supervisor also has an overview of all relevant production figures such as speed and quantities of the packaging lines: Are we on target for production today – or are we lagging behind? Individual assessments – whether monthly, weekly or daily – are all available directly in the dashboard and can be customised to the company’s specific interests and requirements. LEIBINGER Connect enables forward-looking planning and quick responses – well before interruptions or delays occur. For the production manager, this translates into no unplanned downtime, clearer processes and better use of resources – especially when staff is in short supply. LEIBINGER Connect provides these functions without the need for complex software solutions. It brings together what has long been available: data, machines and responsibilities.
ERP connection required
The integration of the machine world plays a key role, especially in companies with SAP as their lead system. LEIBINGER has created a standardised interface to this end, which allows marking data to be used directly in the SAP shop floor. Status messages, consumption values or feedback from the line are immediately available. For IT, this represents another significant step toward greater data consistency. According to the 2024 Industry 4.0 Barometer, many companies still see room for improvement in this area. Even with ambitious digitalisation goals, many systems remain isolated. An SAP connection like this can help bridge the gap between technical reality and strategic requirements. In addition to SAP integration, a universal interface is available that allows LEIBINGER Connect to be integrated into other systems such as ERP, BE, CRM, CMS or quality assurance.
Networking with real impact
Current sector studies show that the need for action has been acknowledged, but implementation often remains sluggish. According to the Industry 4.0 Barometer, Europe lags behind the USA and China in the use of digital technologies. Cross-company data usage in particular continues to be seen as an obstacle. Yet it could contribute significantly to efficiency along the entire supply chain. LEIBINGER Connect addresses this gap with a solution that works immediately, can be integrated flexibly and has a rapid impact.
Digitalisation begins where it has an immediate impact
Many companies are open to digitalisation but find it difficult to get started. According to an Allensbach study, although over 80 per cent of packaging manufacturers are planning or implementing digitalisation measures, only a fraction of them are making consistent use of these opportunities. Digital transformation doesn’t immediately have to encompass the entire factory. Often, a targeted step with a direct impact is enough. LEIBINGER Connect was developed with this in mind: central monitoring of all connected printers via a user-friendly dashboard – for LEIBINGER customers, simple, fast and without any additional hurdles. A tangible contribution to greater transparency, response speed and operational reliability in day-to-day business.
Flexible use – in the cloud or on site
LEIBINGER Connect is a cloud-based platform that meets all standard requirements for data security and interface compatibility. For companies that prefer an on-premises solution, LEIBINGER offers the OPC UA-enabled IQJET printer model, which can also be integrated into highly sensitive IT environments. The platform is also compliant with packaging companies’ data security requirements, for example through encrypted communication and flexible access controls.
More than just a monitor
LEIBINGER Connect offers much so much more than just monitoring. It lays the foundation for sound strategic decisions: What printers are in use and to what extent? In which lines is productivity and utilisation high, and in which lines is maximum production output not being achieved or is utilisation too low? Where can optimisation be achieved and how? Individual evaluations make the system compatible with existing KPIs and optimisation processes. Maintenance notifications, real-time meter readings and flexible data sharing, for example with the responsible LEIBINGER partner on site, complete the picture. The insights gained can help increase overall equipment effectiveness (OEE) in a very targeted manner.
Michael Wöhrmann, Director of Business Development at LEIBINGER, describes it as follows: “When it comes to line performance, attention is usually directed towards the big levers. LEIBINGER Connect shows that greater transparency in coding and marking can have a measurable impact – without requiring any additional project work. For companies, this is often the first practical step towards digitalisation with minimal risk.” Anyone who takes a pragmatic approach to digitalisation in packaging will find an effective starting point here – not at some unspecified point in the future, but exactly when it matters for their business.