E²M, Inc. and Polytron, Inc., of Norcross, Georgia employ the latest technology to provide exceptional design and installation services for a variety of manufacturing and packaging needs. An outstanding example of such technological innovation is their PolySimSM simulation and emulation tool set.

PolySimSM is a dynamic, interactive set of tools that allows testing of new package and manufacturing lines prior to installation. By importing CAD drawings of packaging lines into PolySimSM, E²M/Polytron engineers create a scaled visual representation of the line. PolySimSM then initiates an emulation program that receives information from the Programmable Logic Controller (PLC) and an Human Machine Interface (HMI). As it receives information from these programmed components, PolySimSM models the working packaging line in a real time environment. The system allows our engineers to test and debug programming in the PLC and HMI long before completion of construction of a production line.

Because PolySimSM is actually a system of interactive programs, our engineers have tremendous capacity within the system to account for production and design variables. For instance, as our engineers develop a bottling line, PolySimSM allows them not only to recreate a three-dimensional scaled visual of the line but also to define package dimensions of the product. This allows us to make adjustments to production variables such as motor speed, sensor placements, and control devices to resolve problems in the line design or programming logic at an early stage. In addition, if the client wants to consider changes in the individual product unit, PolySimSM can emulate the effect of those product design variables on the working line by factoring these changes into the emulation along with information received from the PLC. In this way, package format changes can be created and tested long before the line is started up.

PolySimSM offers direct benefits for our clients, including:

Reduced risks by accounting for variables in system design and function - Using PolySimSM, we are able to confirm design logic, test line capability prior to start-up, compare various long-term operational scenarios prior to full line operation, reduce the number of in-field changes, and validate multiple package format parameters;

Reduced costs by maximizing resources and personnel - PolySimSM allows for a much quicker start-up at higher production volume and rates because problems are identified in a line from start to finish. This means that service technicians can be utilized to address problems at all points during the line installation. Product waste is minimized and the length of time that a full integration team needs to remain onsite is reduced;

Reduced time to market - Because programs are tested prior to start-up, PolySimSM allows for an early Factory Acceptance Test (FAT) of system programming. In addition, clients can envision programming and design changes during the FAT and test changeover parameters from one package to another. By accounting for multiple design and packaging variables with great specificity, PolySimSM allows for enhanced training of line employees prior to actual start-up. Finally, all of these benefits lead to increased operational confidence at startup.

Since 1985, Polytron and E²M have been industry leaders in high-quality integrated packaging and process systems. PolySimSM ensures that we will continue to design and install such systems in the most efficient and cost-effective manner possible.

E²M / Polytron - 6734 Jimmy Carter Boulevard, Norcross, GA 30071
1-800-622-4326 - www.e2m.com www.polytron.com