Syntegon is presenting a holistic concept for the 'Factory of the Future'

At the upcoming interpack show, Syntegon is presenting the Factory of the Future. In this context, the strategic lifecycle partner to the pharmaceutical, biotech and food industries is showcasing neXt, the next evolutionary stage in its packaging solutions. NeXt is not intended to be a single machine platform, but instead an integrative automation solution that combines machines, seamless operating concepts and AI/data-based decision support in an operational ecosystem. As such, this innovation is fully in line with Syntegon’s focus on seamless, innovative and lifecycle solutions. 

The Syntegon HFX for flow-wrapping and the Syntegon TRX for topload cartoning are two key neXt system components. Syntegon demonstrates how flexibility, efficiency and operator independence can be successfully achieved in an increasingly complex production environment. 

Addressing the industry’s most pressing challenges 

The food industry is under enormous pressure to change. Non-stop rising costs, an acute shortage of qualified operators, increasing safety and compliance requirements, as well as an ever-growing variety of package sizes and styles are all shaping everyday life in production halls. Production lines need to be quick to change over, intuitive to operate and as independent of manual intervention as possible. This is exactly where the intelligent neXt system architecture comes in, with three clear guiding principles: Seamless Operation, Smart Decisions and Touchless Automation. 

Seamless Operation: Seamless processes, minimal downtime 

Seamless operation is synonymous with end-to-end, seamless processes across all machines integrated into the neXt system architecture. Uniform operating philosophies, harmonized interfaces and a standardized format change concept ensure that operators can immediately find their way around any system, sources of error are reduced, and set-up times are significantly shortened. 

In the case of the new TRX topload cartoning platform, these guided or automated processes enable format changes to be carried out in just ten minutes, while significantly reducing the number of format parts. This minimizes downtime, reduces investment costs for new formats and makes everyday work easier, especially for less experienced operators. Training costs can be significantly reduced – a decisive advantage in times of scarce human resources. 

Smart Decisions: Data-based transparency in real time 

The second pillar, Smart Decisions, brings data intelligence to the packaging line. As part of the operational system, neXt links networked machine platforms with software solutions such as the cloud-based Synexio, machine-based Logbook functions or 3D error views.    

Camera and AI-based quality controls, automatic error detection and status monitoring ensure transparency in terms of productivity, quality and efficiency. This enables operators to monitor line status remotely and respond more quickly to deviations. This results in fewer unplanned downtime, less waste and higher overall equipment effectiveness (OEE). Production managers can make informed decisions – based on data, quickly and in a way that is precisely targeted. 

Touchless Automation: More autonomy, less manual intervention 

Syntegon takes things one step further with Touchless Automation. Within the neXt system architecture, manual intervention is reduced to a minimum and recurring, non-value-adding activities are consistently automated. 

For example, autonomous material supply systems take over the provision and insertion of film reels or cardboard blanks. Autonomous mobile robots (AMRs) supply the machines independently, while high-performance splicing systems in flow-wrapping enable uninterrupted operation. Packaging lines can therefore run for hours without operator intervention. This reduces the workload on staff and increases availability, while freeing up time for truly value-adding tasks. 

Two new machine platforms as building blocks of the system architecture 

To mark the launch of neXt, Syntegon is presenting two new modular machine platforms that are fully integrated into the intelligent system architecture: the HFX flow-wrapping platform for primary packaging and the TRX topload cartoning platform for secondary packaging. 

Both platforms are modular in design and serve as key building blocks within the operational neXt ecosystem. They are retrofit-capable and designed for long-term scalability. New functions, digital features or additional automation modules can also be easily integrated at a later date. 

As a strategic lifecycle partner, Syntegon supports its customers throughout the entire lifecycle of their packaging lines. Flexible Service Agreement packages – from preventive maintenance concepts to comprehensive performance assurance, including spare parts and defined response times – ensure maximum availability, predictable costs and long-term value enhancement of the investment. 

PPWR-ready and energy-efficient 

This all makes the neXt system architecture a future-proof investment that also delivers impressive results in terms of sustainable production strategies: energy- and waste-reducing technologies increase resource efficiency, while the flexible processing of different packaging styles and PPWR-compliant materials gives manufacturers new scope for implementing regulatory requirements. 

This is how Syntegon combines economic performance with ecological responsibility – and with neXt, sets a clear example for a high-performance, flexible and sustainable Factory of the Future.