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Sustainable packaging machine reduces maintenance and wear

How Frugalpac’s Frugal Bottle Assembly Machine cuts environmental impact and downtime with igus components

Frugalpac’s Frugal Bottle Assembly Machine (FBAM-2) , is an innovative manufacturing solution designed to produce sustainable paper bottles which gives beverage and packaging companies the capability to manufacture low carbon bottles at scale, significantly reducing plastic use and producing bottles with a carbon footprint up to six times lower than glass.

Each packaging machine can produce approximately 12 million bottles per year and with local production stretching across the globe from the UK to the USA, Canada and soon Australia, transport costs can be cut, further adding to the low-carbon footprint.

Requirement, challenge and solution

igus mechanical assembly with bolts, pivots and springs in a machine mechanism.

Requirements

The Frugal Bottle Assembly Machine (FBAM-2) is primarily used in the packaging industry, specifically within the food and beverage sector. Its main application is to produce sustainable low carbon paper bottle packaging for global wine, spirits, and edible oils.

It is used by packaging manufacturers focused on sustainable solutions and is designed to lower their environmental impact and meet sustainability targets by replacing traditional carbon-intensive glass and plastic bottles with recyclable paper alternatives.


Frugalpac logo for packaging machine application

Challenge

Frugalpac had the challenge of achieving simple, maintenance-free and extremely lightweight sliding mechanisms for both the FBAM 2 pouch assembly carousel, and for 33 repeat mechanisms carried at high speed by their Multi Carrier system (MSC) induction driven track.

In the case of the pouch handling carousel, igus bushes allowed them to use aluminium shafts and follower plates whereas conventional phosphor bronze bushes or bearings would have required full steel assemblies and they implemented igus energy chain as standard given the proven reliability and performance in previous machines. 

Blue conveyor guides red and blue bottle caps along a packaging machine

Solution

Frugalpac used iglidur IC5 powder coating on their slide rails for its low friction, effective and durable quality. They also used igus energy chains, cables, bushes and linear slides across their operation which they estimate helped them to achieve:

  • A carousel payload saving of around 8KG or 27% compared to steel
  • Use of a smaller and more cost-effective motor and gearbox.
  • Significant raw material and machine cost savings.
  • Reduced downtime and maintenance requirement
We have always found igus helpful and the collaboration and solutions established in our earlier technology meant that this time we were able to build on that previous technical support and go straight to an effective design solution.

John-Paul Grogan

Product Director at Frugalpac Ltd

Technology used in Frugalpac's packaging machines

Chain link from the 1500 series with flexible connected segments.

Energy chains

Energy chains used were:

  • 1500.050.048.0
  • 14.3.100.1
  • E08.30.048
  • E045.16.028.0
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CFTHERMO chainflex cable with green-striped sheath.

Cables

Cables used were:

  • Thermocouple cable- CFTHERMO.K.001
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iglidur plastic plain bearing with flange.

Plain bearings

Both iglidur J flange bearings as well as M250 bearings were used.

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iglidur IC-05 coating powder with a 10 kg bag behind a blue powder pile.

Powder coating

IC-05 low friction powder coating for effective and durable sliding operation.

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Linear guide profile with a central hole and end cap.

Linear guides

drylin W linear guides were used.

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Other food and packaging applications

Reduced wear for packaging machines

Doel Engineering

Packaging and processing machines have very specific requirements in order to operate smoothly and efficiently. The machines used by Doel Engineering were no different. The demand efficiency, continuous operation and hygienic components. When they approached us with friction and wear issues on their mitre bars we were only too happy to take some of the bars away and get them coated for a trial.

Find out more
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Successful cooperation for more than 25 years
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Krones packaging line with conveyor and control panel in a production cell.

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With 700 kegs per hour, a robust and reliable linear axis should be found

Breweries normally have to decide whether to purchase a washing and filling system for non-returnable or returnable kegs. The Innokeg AF-C Transversal from KHS can do both. This is made possible by a unique concept of transport and processing stations. When changing between the stations, one of our maintenance-free special linear axes with considerable dimensions is used. KHS GmbH

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Easy to install and easy to clean
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Machine component with an orange sensor on a packaging line.

Thermoformer PowerPak

Cost-effective, lubrication-free and requiring little maintenance
Resistance to temperature fluctuations and cleaning agents, as well as hygiene and cost-efficiency are important criteria for the selection of machine components from CFS.B. V. In this packaging machine, FDA-compliant iglidur® A180 bearings and temperature-resistant iglidur® X bearings are used.
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Thermoforming system with perforated panel and gripper arm for packaging.

Hygienic plain bearings in sealing units of KHS filling systems

KHS is constantly trying to optimise the processes in its beverage filling systems. In this case, the global market leader went into detail: the bearing technology for the capping units on a beverage filling line was completely rethought in order to find an even more hygienic solution. The machine manufacturer relied on our special bearings for this.

Learn more about this application
Film web in a packaging machine with adjustable guide and tension modules.

Lubrication-free technology for labelling machines

Labelling up to 50,000 containers per hour with just one labelling station - this figure alone is impressive for the newly developed Sleevematic TS from Krones AG. With this system, the company has succeeded in doubling the output compared to its predecessor series

Learn more about this application
application image of the labelling machine

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