Precision, speed and flexibility

BUSINESSES TODAY are under increasing pressure to reduce waste, improve efficiency, cut costs, and operate sustainably. Nowhere is this more critical than in the packaging sector, where millions of parcels leave warehouses daily, often half-empty and filled with unnecessary air and filler materials. This inefficiency leads to wasted carton material, inflated shipping costs, and excessive carbon emissions, highlighting a clear need for change.

With a vision to design a fully automated system capable of resizing every carton to match the true size of its contents, Opitz Packaging Systems, a German-based packaging OEM, partnered with IMI’s Industrial Automation team to create an award-winning, high-performance motion system that is, today, delivering precision, speed and flexibility across multiple packaging functions.

The actuator-driven solution

In an engineering partnership, Opitz and IMI’s Industrial Automation sector designed the desired motion architecture to include multiple actuator series as part of one fully integrated, high dynamic system

The IMI Bahr modular linear actuator platform serves as the foundation of the patented carton volume reducer system, seamlessly integrating IMI Bahr actuators at every stage of the innovative packaging process.

These include supporting the cutting and upper closure function for dust-free carton cutting and flap folding.

Tape is applied to individual parcels with precision and speed, followed by parallel actuator systems that ensure a smooth carton flow across various formats. Finally, actuators enable precise glue application to guarantee secure parcel sealing in readiness for warehouse dispatch.

“Our collaboration with Opitz exemplifies how engineering innovation can address real-world challenges,” said Cihan Halavurt, general management for IMI Bahr products. “By integrating our high-performance motion systems, we’ve created a solution that reduces waste, lowers carbon emissions, and enhances efficiency for the packaging industry.”

Benefits all round

As a result of the innovative motion system, Opitz has seen a raft of efficiency and sustainability benefits. There is now up to 85% less air per package, alongside a reduced carton filler material and carbon emission footprint.  Operational efficiencies have surged with multi-format cartons capable of being processed through one high speed, accurate and reliable automated system.

Florens Fuchs, head of procurement, Opitz Packaging Systems, said. “This partnership has allowed us to bring our vision of a right-size packaging solution to life. The results speak for themselves—up to 85% less air per package, reduced filler materials, and a significant reduction in CO₂ emissions. We’re delighted to have set a new standard for sustainable packaging.”

Such has been the industry impact of the Opitz motion system it was recognised by the German Packaging Institute and won a German National Innovation Award for the automated “right-size packaging solution”.  It was recognised for its sustainability contribution by reducing packaging waste and CO₂ emissions.

www.imiplc.com/industrial-automation