Maverick International Optimizes Packaging Changeover and Sealing Performance

About
Efficiency and quality are paramount in the packaging industry. Maverick International, a global packaging OEM, understands the importance of streamlined machine setup and optimal sealing performance. Manual changeovers and sealing quality affect a manufacturer’s bottom line. Maverick International is recognized as a global leader in the design, development, innovation, and manufacture of stand-up pouches for liquids. Their product lineup includes innovative solutions such as the SUPerBarrel®, SUPerPouch®, SUPerWipes®, and SUPerBota®. The company is committed to sustainability, offering packaging options that significantly reduce the carbon footprint compared to traditional packaging mediums like PET or glass bottles.

Maverick International chose Omron Automation to help automate changeovers and improve sealing consistency to provide their customers with increased flexibility and machine performance.

Challenge
The machine previously struggled with several temperature control issues. The old temperature controller required a firmware update before use, causing setup times to exceed 30 minutes. After powering on, it took a considerable amount of time to stabilize the sealing heaters, further delaying production. This delay affected productivity at the start of every shift. Additionally, the sealing quality was inadequate for lightweight materials, forcing customers to choose between using lower-quality materials or risking product recalls due to improper sealing.

Another efficiency bottleneck was the setup and changeover process. Machines designed to seal various bag sizes required manual adjustments between shifts, which consumed time and introduced the risk of human error. These errors could lead to reduced productivity and, in worst cases, product recalls if the machine wasn’t properly configured.

Solution

For their next-gen packaging solution, Maverick International chose Omron Automation for their comprehensive portfolio, including the NX PLC, NX IO Temperature Control Cards, 1S Servos for tension, NA Series HMI, and the Sysmac automation platform. By equipping the machine’s adjustment axis with 1S servos, Maverick fully automated the changeover process, allowing users to select the desired recipe on the HMI and have the machine adjust to the new format almost instantly.

Maverick also integrated OMRON’s NX IO temperature controllers, which provided immediate functionality without lengthy setups. OMRON, a global leader in temperature control since the 1960s, brought its expertise in PID control to the table. The upgrade included Automatic Filter Adjustment technology, which compensates for measurement disturbances to ensure consistent seal quality—especially useful for handling material variations like eco-friendly films, by improving temperature control accuracy and reducing waste. The advanced technology, available both as panel-mounted controllers and PLC cards, seamlessly integrated into the PLC program and automated PID tuning for the user.

Result

Maverick International’s upgrades led to major improvements in their packaging equipment. By adopting the Sysmac automation platform, they fully automated the changeover process, increasing output and improving sealing performance over manual methods. The combination of the NX 102 for control and 1S servos for motion optimized startup and changeover times, ensuring precise tension control, reducing waste, and enhancing both product quality and productivity. These upgrades reduced setup times and increased overall efficiency.

The integration of NX IO temperature controllers enabled instant setup and precise temperature regulation, further improving seal quality and minimizing material waste. With synchronized motion technology from the 1S servo motors, Maverick now produces lightweight, durable packaging that meets ASTM standards while significantly reducing waste.

Moreover, Maverick benefited from Omron’s global support network, including technical assistance, local engineering expertise, and access to specialists. This strong partnership further optimized their manufacturing processes, resulting in higher output, greater flexibility, and more sustainable packaging solutions.