Packaging Machinery

Wrapped Up Faster Than It Can Be Unpacked

Precision, Protection and Efficiency – Clutch and Brake Systems for Packaging Machinery

High Cycle Rates Demand Precise and Reliable Drive Technology

Packaging machines operate at high speeds, with exceptional repeatability and often around the clock. Products are fed, positioned, dosed, sealed, labelled and transported through the production line. Numerous individual movements must work together perfectly. Even a minor deviation can result in faulty packaging, material waste or downtime across the entire line.

The challenge increases when a single machine must handle different formats, materials or products. Films, cartons, bottles, cups and boxes each require their own motion profiles and switching characteristics.

Drive technology must therefore be flexible while delivering reliable performance in every cycle.

Couplings and brakes play a key role in this process. They connect and disconnect drivetrains, synchronise axes, secure positions and protect machinery from overload. To do so, they must switch quickly, transmit torque precisely and operate with minimal wear, even at high cycle rates.

When Every Cycle Counts

Mönninghoff components can be used throughout a wide range of packaging machinery applications, including

Feeding and conveyor systems
Dosing and filling equipment
Vertical and horizontal form-fill-seal machines
Cartoning and folding carton machines
Blister packaging and thermoforming systems
Labelling and sealing equipment
Winding systems and film guidance units
Palletising and end-of-line packaging systems
Format-change and positioning mechanisms
Drives for rollers, conveyors and grippers
Automated changeover and locking mechanisms

Motion requirements vary depending on the machine type. A dosing axis must operate with controlled, repeatable precision. A conveyor requires reliable power transmission over extended operating periods. During format changes, assemblies must be repositioned quickly and then held securely in place.

What all applications have in common is the need to combine speed with accuracy. A fast packaging process is only efficient if the final package is correct.

Requirements for Couplings and Brakes

Packaging machinery places particularly demanding requirements on drive technology:

High cycle rates: Components must handle large numbers of switching operations and movement cycles with consistent performance.
Precise synchronisation: Conveyors, dosing systems, grippers, rollers and packaging tools must work together accurately.
Short switching times: Drives and drive branches must engage and disengage without unnecessary delays.
High repeatability: Production cycles should be performed under consistent conditions.
Reliable holding functions: Assemblies must remain securely positioned during changeovers, maintenance and downtime.
Overload protection: Blockages and operator errors should not cause disproportionate damage to machinery and tooling.
Variable loads: Different products, packaging materials and formats place varying demands on the machine.
Compact design: Available installation space is often limited.
Low wear: Long service life is essential where switching frequencies and operating hours are high.
Effective thermal management: Repeated engagement and braking operations can generate significant heat.
Energy efficiency: Component energy consumption directly affects operating costs over long production runs.
Ease of maintenance: Maintenance and format changes should be quick and predictable.
Seamless integration: Couplings and brakes must fit smoothly into existing mechanical, control and sensor systems.

Drive technology must achieve several objectives simultaneously: fast switching, precise torque transmission, reliable holding and effective machine protection. Only the interaction of these functions creates a stable packaging process.

Synchronise, Protect and Keep Production Moving

Mönninghoff develops clutch and brake systems tailored to the torque, speed, load profile, cycle rate, switching frequency and installation space requirements of each packaging machine.

Electromagnetic Tooth Clutches

Electromagnetic tooth clutches provide precise, positive engagement. They are ideal where drive branches, tooling stations or rotary functions must be connected and disconnected accurately.

Typical applications include

Engaging and disengaging drive axes
Switching format and tooling stations
Synchronising drive stages
Positioning functions within changeover and locking mechanisms
Switching auxiliary drives
Applications requiring minimal backlash

The positive mechanical connection supports precise torque transmission and excellent repeatability. This is particularly important where tooling or axes must return to exactly the same position after every switching cycle.

Overload Clutches

Overload clutches can interrupt power transmission whenever a predefined torque limit is exceeded. This helps protect machinery against damage caused by blockages, jammed packages, foreign objects or operating errors.

Typical applications include

Protection of conveyor and transport systems
Safeguarding dosing and feeding units
Protecting grippers and packaging tools
Limiting torque during product or format changes
Preventing secondary damage to shafts, bearings and gearboxes
Rapid drivetrain disengagement during fault conditions

Key specification parameters include required torque, operating speed, release characteristics and reset behaviour after an overload event. The objective is a protection concept that safeguards the machine while enabling rapid resumption of production.

Magnetorheological Fluid Brakes

Magnetorheological fluid brakes provide continuously adjustable braking torque and damping. They are particularly suitable where materials must be guided, tensioned or decelerated smoothly and under control.

Typical applications include

Dosing and feeding movements
Winding and unwinding processes
Film and material guidance systems

Controlled braking of rollers and reels
Variable load conditions associated with different packaging materials
Motion damping and overrun control
Positioning tasks requiring finely controlled braking

The adjustable braking characteristic allows torque to be matched precisely to the process, helping to stabilise material flow and machine movement without introducing unnecessary forces into the system.

Electromagnetic Multi-Disc Clutches

Electromagnetic multi-disc clutches are designed for frequent switching operations and high torque transmission in a compact package. They are suitable wherever drive functions must be engaged and disengaged regularly.

Typical applications include

Switching conveyor and transport drives
Connecting motors, gearboxes and driven shafts
Frequent start-stop operations
Engaging and disengaging auxiliary equipment
Applications with variable loads and long operating periods

A properly specified multi-disc clutch can provide a robust, low-maintenance solution for repetitive switching duties. The key is matching the clutch to the required torque, speed, switching frequency and thermal load.

Holding Brakes

Following a movement, assemblies often need to remain precisely positioned. Holding brakes can securely maintain the position of axes, tooling systems, lifting units and format-change mechanisms during standstill.

Typical applications include

Format changes and machine set-up procedures
Vertical axes and lifting movements
Maintenance and cleaning positions
Holding during fault conditions
Positioning functions in packaging tools
Emergency-stop and safety functions

Depending on the application, an electromagnetic tooth holding brake can provide a compact, positive-locking holding solution. Holding torque, switching time and safety requirements must be matched to the specific machine design.

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Precision Drive Technology for Stable Packaging Processes

Whether feeding, dosing, film handling, format changes or end-of-line packaging, Mönninghoff develops couplings, brakes and overload protection systems for packaging machinery that demand high cycle rates, precision, protection and long service life.

Are you developing a new packaging machine, modernising an existing production line or looking for a compact solution for switching, holding and overload protection? Speak with our experts about torque, speed, cycle rates, load profiles, material handling and installation space. Together, we can help keep your processes running reliably, cycle after cycle.

High Cycle Rates Require Stable Mechanics

In packaging machinery, even small inaccuracies can become significant across thousands of cycles. Backlash, vibration, overrun or inadequate holding functions can lead to scrap and unnecessary downtime.

Key design considerations may include:

Torque and rotational speed
Acceleration and deceleration profiles
Inertia of moving assemblies
Cycle rates and cycle times
Switching frequency and daily operating hours
Product and packaging formats
Material characteristics of films, paper, carton and labels
Required positioning accuracy
Backlash and torsional stiffness
Vibrations and potential resonance effects
Thermal loading during continuous operation
Behaviour under blockage and overload conditions
Response during power failures and emergency stops
Available installation space and connection geometry
Control, sensing and diagnostic requirements
Maintenance, cleaning and changeover concepts

Mönninghoff develops solutions tailored to the complete motion-control task. A clutch or brake is correctly specified not only when it meets technical requirements, but when it also complements the machine's cycle rate, material flow and safety concept.

Protection and Availability Go Hand in Hand

An overload event should protect the machine without removing it from production longer than necessary. For this reason, drive technology must be considered alongside controls, sensors and operator interaction.

Depending on the application, important functions may include:

Defined interruption of power transmission during overload
Safe shutdown in the event of a blockage

Controlled braking of rollers and axes
Monitoring of switching and holding states
Rapid fault detection
Safe reset following production stoppages
Easy accessibility for maintenance and replacement
Integration into existing safety and control systems

The specific safety function should always be evaluated as part of the overall machine concept and risk assessment. In packaging, what matters is not only how fast a machine runs, but also how quickly it can return to operation.

From Development to Series Production

For customised packaging machinery, prototypes and functional samples can help validate the final solution at an early stage. Particularly at high cycle rates, it is beneficial to evaluate switching performance, thermal behaviour and durability long before the production machine is completed.

Typical evaluation criteria include

Switching time and switching reliability
Positioning accuracy and repeatability
Torque transmission under varying loads
Response to blockages and overload situations
Braking torque and deceleration performance
Behaviour with different products and packaging formats
Thermal loading at high cycle rates
Endurance performance and wear characteristics
Response during power failures and emergency stops
Integration with mechanics, controls and sensors
Maintenance and format-change procedures
Performance within the complete production line

This allows design adjustments to be implemented at an early stage, reducing later modifications and providing a solid foundation for a reliable production solution.