In packaging automation, speed and output often get the spotlight. But behind every high-performing machine is another factor that directly impacts efficiency, flexibility, and operating cost: system architecture.
For decades, pneumatic systems - those using compressed air - have been the standard for many packaging applications. They’re familiar, widely used, and capable of handling repetitive motion at high speeds. But they also come with limitations, including compressed air infrastructure, energy consumption, maintenance requirements, and reduced flexibility in compact production environments.
Today, manufacturers are beginning to rethink that model, not by improving pneumatics, but by eliminating them altogether.
Modern packaging operations face increasing pressure to do more with less. At the same time, sustainability initiatives are pushing OEMs and end users to reduce utility demand and improve overall system efficiency. That’s why more machine builders are moving toward fully-electric automation architectures.
In the case of Hugo Beck’s horizontal flowpack machine, the goal was clear: create a compact, modular, and highly efficient packaging solution without relying on compressed air.
The result was a fully automated HFFS machine powered entirely by SEW-EURODRIVE automation technology.
Compressed air is often treated as a standard utility in manufacturing, but it’s also one of the least efficient forms of energy in industrial systems.
Leaks, pressure losses, maintenance demands, and continuous energy consumption can significantly increase operational costs over time. In packaging environments, pneumatic systems also introduce additional complexity through:
And while these systems are capable, they can limit flexibility, especially in applications where space, modularity, and energy efficiency matter most.
Rather than building around pneumatic technology, Hugo Beck redesigned its flowpack R machine around fully electric automation. Using coordinated hardware and software from SEW-EURODRIVE, the machine replaced pneumatic functions with advanced stepper technology and integrated automation components.
The result is a packaging system that is:
And importantly, more adaptable to changing production requirements.
The solution included:
One of the biggest advantages of eliminating compressed air is design freedom.
Without pneumatic infrastructure, machines can operate in tighter spaces and require fewer external utilities. According to Hugo Beck, the move to a single-phase 230 V connection significantly improved installation flexibility while reducing overall system complexity.
That flexibility matters in modern production environments where:
The simpler the infrastructure, the easier it becomes to scale and adapt production lines.
|
"Thanks to the 1-phase power supply and completely eliminating the need for compressed air, the machine is more versatile and can be operated in the tightest of spaces. Its output is now also up to 50% higher.” – Timo Kollmann, Managing Director at Hugo Beck Maschinenbau GmbH & Co. KG |
A common misconception is that moving away from pneumatics means sacrificing machine speed or throughput. In reality, intelligent electric automation can improve both.
The fully automated flowpack system achieved output increases of up to 50% while supporting paper packaging applications running at up to 150 cycles per minute.
This demonstrates an important shift in packaging automation: Efficiency and performance are no longer tradeoffs. With coordinated motion control and integrated software, manufacturers can improve throughput while simultaneously reducing energy consumption and infrastructure requirements.
Another major advantage of fully-electric automation is integration. Instead of relying on disconnected subsystems, modern packaging machines can operate through a unified automation architecture where motion, control, safety, and diagnostics work together seamlessly.
Integrated software libraries, such as MOVIKIT® FFS, simplify implementation while enabling machine-specific functionality directly within the controller environment.
This reduces engineering complexity and supports faster commissioning, easier troubleshooting, and greater scalability over time.
Sustainability in packaging is no longer limited to materials alone.
It now includes:
By eliminating compressed air and reducing overall system complexity, fully electric packaging systems help manufacturers align operational efficiency with broader sustainability goals.
In this case, the transition supported both film and paper packaging applications while improving flexibility and reducing energy demand.
Because the future of packaging automation isn’t just faster. It’s smarter, more flexible, and fully connected.