Food Processing and

Packaging Machinery
Association

DIN 8743: Packaging machines and packaging installations,

time related definitions, reference factors and calculation
fundamentals

Translation not certified by DIN.

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005)

Contents Page

National Preface..................................................................................................................................................3
Introduction.........................................................................................................................................................3
1 Area of application ................................................................................................................................3
2 Normative References...........................................................................................................................4
3 Definitions ..............................................................................................................................................4
3.1 Time definitions .....................................................................................................................................4
3.1.1 Machine working time ...........................................................................................................................4
3.1.2 Machine downtime ................................................................................................................................5
3.1.3 Machine operationg time ......................................................................................................................6
3.1.4 Machine running time ...........................................................................................................................6
3.1.5 Breakdown time .....................................................................................................................................6
3.1.6 Empty running time ...............................................................................................................................7
3.1.7 Waste running time ...............................................................................................................................7
3.1.8 Quality time ............................................................................................................................................8
3.1.9 Lost time.................................................................................................................................................9
3.2 Reference factors ................................................................................................................................11
3.2.1 General .................................................................................................................................................11
3.2.2 Reference factors for packaging machines......................................................................................11
3.2.3 Reference factors for packaging installations .................................................................................14
3.3 Definitions for the structures of packaging installations................................................................16
3.3.1 Sequential linkage ...............................................................................................................................16
3.3.2 Parallel linkage of identical elements................................................................................................17
3.3.3 Parallel linkage of different elements ................................................................................................17
4 Definition of the reference factors .....................................................................................................18
4.1 Definition of the reference factors for packaging machines ..........................................................18
4.2 Definition of the reference factors for packaging installations .....................................................18
4.2.1 General .................................................................................................................................................18
4.2.2 Data collection .....................................................................................................................................18
4.2.3 Calculation ...........................................................................................................................................19
4.2.4 Simulation ............................................................................................................................................20
Appendix A (normative) Formula symbols......................................................................................................21
Appendix B (normative) Types of linkage of packaging installations..........................................................23
B.1 Sequential linkage ...............................................................................................................................23
B.2 Parallel linkage of identical elements................................................................................................27
B.3 Parallel linkage of different elements ................................................................................................31
Bibliographical References .............................................................................................................................35

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National Preface
This Norm was compiled in DIN from the specialised packaging machine section of the NAM (Norm
Committee for Machine Manufacture).

Alterations:

The following upgrading has been made to DIN 8743: 1987-2001

a) The introduction of more definitions

b) The defining of more reference factors

c) The compilation of reference factors for packaging installations

Introduction

The operation of packaging machines and whole packaging installations is subject to countless influences
from the machines themselves and associated equipment, from the upstream and downstream units, the
product being packed, the packaging materials, any ancillary packaging means, the production organisation,
the operating and maintenance personnel and the environmental conditions in the packaging area. Because
of this the packaging process does not run uninterruptedly but rather is interrupted by part planned and part
accidental disruptions. During the operation of packaging machines or installations the periods in which
production is carried out efficiently and qualitatively alternate at random with periods in which waste,
downtime and stoppage occur.The characterisation of the performance of a packaging machine or
installation in operation results from reference factors which are constructed from time segments based on
the structural pattern of the machine running time. From this for example the reference factors of total
machine efficiency, total machine availability or operating output can be evaluated as well as stoppages or
loss allocated to their respective causes.

1 Area of operation
This Norm applies to the field of packaging technology. The prescriptions of this norm establish a basis for
the identification of operating performance and for the evaluation of the functionality of technical equipment
designed for the packaging of products. This can be either individual packaging machines or whole
packaging installations consisting of linked packaging machines and in-line ancillary equipment.

This Norm serves to increase the understanding between manufacturers and users of packaging machines
and installations about the efficiency and performance of such equipment.

This Norm does not apply to liquid filling equipment, see DIN 8782 and DIN 8783

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) -3-

2 Normative references
This Norm contains, through dated or undated references, statements and conclusions from other
publications. These normative references are cited at the respective places in the text and the publications
are listed at the conclusion of this Norm. With dated references later alterations or revisions of these
publications only apply to this Norm in those case where they are inserted through an amendment or
revision. With undated references the latest issue of the mentioned publication applies (including
amendments)

DIN 8728 - Drinks - filling equipment, definitions for filling lines and individual units.

DIN 8783 - Drinks - filling equipment, investigative analysis of filling equipment technology

Norms in the sequence DIN 55405, Definitions for the packaging industry.

DIN EN 415-1 Safety of packaging machines Part 1: Terminology and Classification of the Designation for
packaging machines and ancillary equipment; German Version EN 415-1

3 Definitions
In the use of this Norm the following definitions and those given in DIN 55405-1 to DIN 55405-7 and
DIN EN 415-1 apply.

3.1 Time definitions

Machine working time tm

Operating time tbtr Downtime tneb

Running time tl Breakdown time ta

Quality time tq Waste running time Empty running time

taus tle

Lost time tv

Picture 1 – Classification of the time definitions

3.1.1 Machine working time

Machine working time of a packaging machine tm

time which is available for production with the packaging machine or time available for its observation or
investigation

NOTE This is the sum of the operating time of the packaging machine tbtr (3.1.3.1) and the downtime of the
packaging machine tneb (3.1.2.1)

t m = t btr + t neb (1)

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Machine working time of a packaging installation tmA

time which is available for production with the packaging installation or time available for its observation or
investigation

NOTE This is the sum of operating time of the packaging installation tbtrA (3.1.3.2) and the downtime of the
packaging installation tnebA (3.1.2.2)

tmA = tbtrA + tnebA. (2)

3.1.2 Downtime

3.1.2.1 Downtime of a packaging machine tneb

is the sum of the times which through either prescribed or planned or other agreed activity on the machine
are not available for machine operation

NOTE 1 To these belong

⎯ Activities at beginning and end of shift;

⎯ Planned preparation and retooling changeover times;
⎯ Stoppages for the resupply of product, packaging materials and other resource;
⎯ Cleaning and Sterilising;
⎯ Preventative repairs, e.g. exchange of wearing parts, correction to the machine controls, insofar as they fall within
the sphere of the machine working time;
⎯ Running in phase until the first pack of acceptable quality is produced.

NOTE 2 The definition of an acceptable quality pack is one which complies with the full scope of the specification.

3.1.2.2 Downtime of a packaging installation tnebA

is the sum of the times which through either prescribed or planned or other agreed activity on the installation
are not available for machine operation.

With packaging installations only those time segments count as downtime in which the entire installation can
not work.

NOTE 1 To these belong

⎯ Activities at beginning and end of shift;

⎯ Planned preparation and retooling changeover times;
⎯ Stoppages for the resupply of product, packaging materials and other resource;
⎯ Cleaning and Sterilising;
⎯ Preventative repairs , e.g. exchange of wearing parts, correction to the machine controls, insofar as they fall within
the sphere of the installation working time;
⎯ Running-in phase until the first pack of acceptable quality is produced.

NOTE 2 Downtime e.g. through change-overs to individual machines within the installation can be absorbed by
means of existing buffers so that the work of the installation itself is not interrupted.

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3.1.3 Operating time

3.1.3.1 Operating time of a packaging machine tbtr

Machine working time of the packaging machine tm (3.1.1.1) minus the downtime of the packaging
machine tneb (3.1.2.1):

t btr = t m − t neb (3)

3.1.3.2 Operating time of a packaging installation tbtrA

Machine working time of the packaging installation tmA (3.1.1.2) ) minus the downtime of the packaging
installation tnebA (3.1.2.2):

t btrA = t mA − t nebA (4)

3.1.4 Running time

3.1.4.1 Running time of a packaging machine tl

Sum of the times in which the packaging machine is running, irrespective of whether it is producing
acceptable quality packs or rejectable waste, whether it is running empty or with reduced operating speed

NOTE The running time is the result of the operating time of the packaging machine tbtr (3.1.3.1) minus the
breakdown time ta (3.1.5.1).

t l = t btr − t a (5)

3.1.4.2 Running time of a packaging installation tlA

Sum of the times in which the packaging installation is running, irrespective of whether it is producing
acceptable quality packs or rejectable waste, whether it is running empty or with reduced operating speed.

NOTE 1 The running time is the result of the operating time of the packaging installation tbtrA (3.1.3.2) minus the
breakdown time taA (3.1.5.2):

t lA = t btrA − t aA (6)

NOTE 2 To the running times belong also the times in which for example with parallel organised machines not all
machines are running or stoppages with individual machines are absorbed through buffers..

3.1.5 Breakdown time

3.1.5.1 Breakdown time of a packaging machine ta

Sum of the times in which the packaging machine is not running because a breakdown criterion arises

NOTE 1 To the breakdown criteria belong for example accidental technical defects, queuing of product or missing
packaging materials. The breakdown time is a component of the lost time, it can have either a technical or
organisational cause..

NOTE 2 The downtime (tneb) does not count as lost time.

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3.1.5.2 Breakdown time of a packaging installation taA

Sum of the times in which the packaging installation is not running because a breakdown criterion arises.

NOTE 1 To the breakdown criteria belong for example accidental technical defects, queuing of product or missing
packaging materials. The breakdown time is a component of the lost time, it can have either a technical or
organisational cause

NOTE 2 Packaging installations could run as well if necessary if several installation elements break down. A break
down of a packaging installation is to be considered as the stoppage of the bottle neck machine.

NOTE 3 The downtime (tneb) does not count as lost time.

3.1.6 Empty running time

3.1.6.1 Empty running time of a packaging machine tle

Sum of the times in which the packaging machine is running but not producing any packs

NOTE 1 Causes of this are for example interrupted product flow and/or packaging material supply

NOTE 2 The empty running time can also be calculated from the number of empty cycles and the target output of the
packaging machine:

nle
t le = (7)
q est

whereby nle is the number of empty cycles and qest is the target output of the packaging machine (see 3.2.2.1.2)

3.1.6.2 Empty running time of a packaging installation tleA

Sum of the times in which the packaging installation is running but not producing packs

NOTE 1 Causes of this are for example interrupted product flow and/or packaging material supply.

NOTE 2 The empty running time can also be calculated from the number of empty cycles and the taget output of the
packaging installation:

nleA
t leA = (8)
q estA

whereby nleA is the number of empty cycles and qestA is the target output of the packaging installation (see 3.2.3.1.2)

3.1.7 Waste running time

3.1.7.1 Waste running time of a packaging machine taus

Sum of the times in which the packaging machine is producing waste

NOTE 1 The waste running time can also be calculated from the number of waste packs and the target output of the
packaging machine:

naus
t aus = (9)
qest

whereby naus is the number of empty packs and qest is the target output of the packaging machine ( see 3.2.2.1.2)

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NOTE 2 The running in phase until the first pack of acceptable quality is produced does not belong to the waste
running time.

3.1.7.2 Waste running time of a packaging installation tausA

Sum of the times in which the packaging installation is producing waste

NOTE 1 The waste running time can also be calculated from the number of waste packs and the target output of the
packaging installation:

n ausA
t ausA = (10)
q estA

whereby nausA is the number of empty packs and qestA is the target output of the packaging installation ( see 3.2.3.1.2)

NOTE 2 For the purposes of comparison, where a packaging installation is performing more than one packaging
process (eg primary packaging, point of sale packaging, collation unit) it is the number of primary packages
which is to be used for this calculation.

NOTE 3 The running in phase until the first pack of acceptable quality is produced does not belong to the waste
running time

3.1.8 Quality time

3.1.8.1 Quality time of a packaging machine tq

Sum of the times in which the packaging machine produces packs of acceptable quality.

NOTE 1 The quality time is calculated from the actual number of packs of acceptable quality (nbtr) and the target
output (qest) of the packaging machine.

nbtr
tq = (11)
qest

whereby nbtr is the actual number of packs of acceptable quality and qest is the target output of the packaging machine
(see 3.2.2.12)

3.1.8.2 Quality time of a packaging installation tqA

Sum of the times in which the packaging installation produces packs of acceptable quality

NOTE 1 The quality time is calculated from the actual number of packs of acceptable quality (nbtrA) and the target
output (qestA) of the packaging installation.

nbtrA
t qA = (12)
q estA

whereby nbtrA is the actual number of packs of acceptable quality and qestA is the target output of the packaging
installation (see 3.2.3.1.2)

NOTE 2 For the purposes of comparison, where a packaging installation is performing more than one packaging
process ( e.g. primary packaging, point of sale packaging, collation unit) it is the number of primary
packages which is to be used for this calculation.

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3.1.9 Lost time

3.1.9.1 Lost time of a packaging machine tv

Sum of the times in which the packaging machine, through breakdown, empty running or waste production,
does not produce any packs of acceptable quality.

NOTE 1 The losses caused through waste running, empty running or breakdowns can be classified as either
technical (tvt) or organisational (tvo). The technically caused lost time is subdivided into machine related
(tvtm) and machine external(tvtf )

3.1.9.1.1 Technically caused lost time of a packaging machine (tvt)

3.1.9.1.1.1 Machine related, technically caused lost time (tvtm)

Sum of the lost times which arise from breakdowns or faults in the packaging machine (working elements ,
controls, drive, setting up and adjustment systems, transport system, etc.)

NOTE 1 To the machine related breakdowns belong for example:

⎯ Interruptions in the the flow of packaging materials and products ( such as blockages and jam ups) which are due to
a failure of the working elements of the machine;
⎯ Destruction of packaging materials, product or pack which is due to a failure of the working elements of the machine
and the consequent cleaning operation;
⎯ Failure of the controls and the necessary corrective action;
⎯ Adjustment and replacement of machine parts during the operating time;
⎯ Machine repairs.

3.1.9.1.1.2 Machine external, technically caused lost time tvtf

Sum of the lost times due to machine breakdowns whose cause lies outside the scope of the packaging
machine, ie such as the product, packaging materials, or packs.

NOTE 1 To the machine external breakdowns belong for example:

⎯ Functional disruption due to non conformance with the specification, ie tearing of packaging material due to
inadequate mechanical strength or weak spots, variation in the physical properties of the product;
⎯ Blockages due to any deviations in size, shape and location;
⎯ Cleaning and maintenance caused by breakdown of an upstream process.

3.1.9.1.2 Organisationally caused lost time of a packaging machine tvo

Sum of the lost times which arise from disruption in the organisational area (e.g. the production organisation,
upstream and downstream process management, operating and maintenance personnel, supply means,
etc.)

NOTE 1 To the organisational causes belong for example:

⎯ Unplanned changeover or conversion times on the machine due to non conformance in the specification of
packaging materials, product or packaging ancillaries;
⎯ Unplanned machine stoppage or empty running due to missing product, packaging materials or packaging
ancillaries;
⎯ Unplanned machine stoppage or empty running due to breakdown in the upstream equipment;
⎯ Unplanned machine stoppage or empty running due to breakdown in the downstream equipment;
⎯ Operating errors;
⎯ Missing operating or maintenance personnel;
⎯ Disruption of the supply means;
⎯ Act of God.

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3.1.9.2 Lost time of a packaging installation tvA

Sum of the times in which the packaging installation, through breakdown, empty running or waste
production, does not produce any packs of acceptable quality.

NOTE 1 The losses caused through waste running, empty running or breakdowns can be classified as either
technical tvtA or organisational tvoA. The technically caused lost time is subdivided into installation related
tvtfA and installation external tvtfA

3.1.9.2.1 Technically caused lost time of a packaging installation tvtA

3.1.9.2.1.1 Installation related, technically caused lost time tvtmA

Sum of the lost times which arise from breakdowns or faults in the packaging installation (working elements,
controls, drive, setting up and adjustment systems, transport system, etc.)

NOTE 1 To the installation related breakdowns belong for example:

⎯ Interruptions in the flow of packaging materials and products (such as blockages and jam ups) which are due to a
failure of the working elements of the installation;
⎯ Destruction of packaging materials, product or pack which is due to a failure of the working element of the
installation and the consequent cleaning operation;
⎯ Failure of the controls and the necessary corrective action;
⎯ Adjustment and replacement of installation parts during the operating time.

3.1.9.2.1.2 Installation external, technically caused lost time tvtfA

Sum of the lost times due to installation breakdowns, whose cause lies outside the scope of the packaging
installation, i.e. such as the packaging materials, product or pack.

NOTE To the installation external breakdowns belong for example:

⎯ Functional disruption due to non conformance with the specifiaction, ie tearing of packaging material due to
inadequate mechanical strength or weak spots, variation in the physical properties of the product;
⎯ Blockages due to any deviation in size, shape or location;
⎯ Cleaning and maintenance caused by breakdown in an upstream process.

3.1.9.2.2 Organisationally caused lost time of a packaging installation tvoA

Sum of the lost times which arise from disruption in the organisational area (e.g. the production organisation,
upstream and downstream process management, operating and maintenance personnel, supply means,
etc.)

NOTE 1 To the organisational causes belong for example:

⎯ Unplanned changeover or conversion times on the installation due to non conformance in the specification of the
packaging materials, product or packaging ancillaries;
⎯ Unplanned installation stoppage or empty running due to missing product, packaging materials or packaging
ancillaries;
⎯ Unplanned installation stoppage or empty running due to breakdown in the upstream equipment;
⎯ Unplanned installation stoppage or empty running due to breakdown in the downstream equipment;
⎯ Operating errors;
⎯ Missing operating or maintenance personnel;
⎯ Disruption of the supply means;
⎯ Act of God

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3.2 Reference Factors

3.2.1 General

The reference factors serve to characterise and act as an assessment of the operating performance of a
packaging machine or installation under concrete conditions. They are compiled from the recorded times, the
time calculations and from the registered volumes. They facilitate the standardised and measureable
assessment of a packaging machine or installation in contracts or agreements, the proving of fulfillment of
claimed performance and the comparison in performance of packaging machines or installations.

3.2.1.1 Output

Produced or produceable number of packs per time unit

NOTE Quantity based reference factor, synonymous with the terms productivity, throughput, and production
efficiency

3.2.1.2 Availability

Proportion of time in which the packaging machine or installation is available, measured against the
appropriate total time.

NOTE Time based reference factor

3.2.1.3 Efficiency rate

Relationship between the produced and produceable number of packs

NOTE 1 dimensionless reference factor

NOTE 2 with constant target output the value for machine availability and for efficiency rate is the same.

3.2.2 Reference factors for packaging machines

3.2.2.1 Output of a packaging machine q

3.2.2.1.1 Nominal rated output of a packaging machine qn

The maximum number of acceptable quality packs (nmax) per time unit for which the packaging machine,
under the assumption of defined ideal conditions regarding machine condition, packaging materials,
packaging ancillaries, product and operating personnel, was designed:

n max
qn = (13)
t
whereby nmax is the maximum number of acceptable quality packs from the packaging machine and t the time unit.

NOTE 1 The nominal output is a theoretical value

NOTE 2 Packaging machines which for example can produce several pack sizes have correspondingly several
nominal outputs.

NOTE 3 The time unit t can be for example a shift, an hour or a minute.

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3.2.2.1.2 Target output of a packaging machine qest

mathematical number of acceptable quality packs (nest) per time unit which the packaging machine at the set
working speed and with uninterrupted running and disruption free production produces:

nest
qest = (14)
t

whereby nest nest is the mathematical number of acceptable quality packs from the packaging machine and t
the time unit.

NOTE 1 The nominal output is the upper limiting value for the target output.

NOTE 2 The target output is dependent on the package type and size, the packaging materials and ancillaries, the
product and the system of pack closure.

NOTE 3 The time unit t can for example be a shift, hour or a minute.

3.2.2.1.3 Operating output of a packaging machine qbtr

actual number of acceptable quality packs (nbtr ) which are produced by the packaging machine within the
operating time (tbtr):

nbtr
qbtr = (15)
tbtr

Whereby nbtr is the actual number of acceptable quality packs from the packaging machine and tbtr is the
operating time ( 3.1.3.1)

NOTE 1 It takes into account all lost times ( 3.1.9.1)

NOTE 2 It is an empirical value

NOTE 3 By definition is qbtr < qest

3.2.2.1.4 Running time output of a packaging machine ql

actual number of acceptable quality packs (nbtr), ) which are produced by the packaging machine during
running time (tl):

nbtr
ql = (16)
tl

NOTE By definition is qest > ql > qbtr

3.2.2.1.5 Effective output of a packaging machine qeff

actual number of acceptable quality packs (nbtr) which are produced by the packaging machine based on the
operating time (tvtf) after reduction for machine external (tbtr) and organisationally caused (tvo) lost times:

nbtr
qeff = (17)
tbtr − t vtf − t vo

NOTE The effective output takes into consideration only the machine related lost times (3.1.9.1)

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3.2.2.2 Availability of a packaging machine v

3.2.2.2.1 Total availability of a packaging machine vg

Relationship of the time in which the packaging machine is producing to an acceptable quality to the
operating time (quality time tq), to the operating time (tbtr) expressed as a percentage:

tq
vg = × 100 (18)
t btr

3.2.2.2.2 Technical availability of a packaging machine vt

Relationship of the time in which the packaging machine is producing to an acceptable quality (quality time
tq), to the operating time after reduction for the organisationally caused lost times expressed as a
percentage:

tq
vt = × 100 (19)
tbtr − tvo

3.2.2.2.3 Machine technical availability vm

Relationship of the time in which the packaging machine is producing to an acceptable quality (quality time
tq) to the operating time after reduction for machine external and organisationally caused lost times,
expressed as a percentage

tq
vm = × 100 (20)
t btr − t vtf − tvo

3.2.2.3 Efficiency rate of a packaging machine η

3.2.2.3.1 Total efficiency rate of a packaging machine ηg

Relationship of the operating output (qbtr) to the maximum possible output at the set working speed (target
output qest), expressed as a percentage:

qbtr
ηg = × 100 (21)
q est

3.2.2.3.2 Technical efficiency rate of a packaging machine ηt

Relationship of the operating output (qbtr) to the target output (qest) after reduction for restorative losses
occasioned in the organisationally caused lost time (tvo), expressed as a percentage:

qbtr
ηt = × 100 (22)
qest ⋅ (1 − (t vo / tbtr ) )

3.2.2.3.3 Machine technical efficiency rate ηm

Relationship of the effective acceptable quality output (qeff ) to the produceable production quantity (qest) at
the set working speed and with uninterrupted running and disruption free production, expressed as a
percentage:

q eff
ηm = × 100 (23)
q est

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3.2.3 Reference factors for packaging installations

3.2.3.1 Output of a packaging installation qA

3.2.3.1.1 Nominal rated output of a packaging installation qnA

maximum number of acceptable quality packs (nmaxA) per time unit for which the packaging installation, under
the assumption of defined ideal conditions with regard to the condition of the installation, the packaging
materials and ancillaries, the product and the operating personnel, was designed:

n max A
qnA = (24)
t
whereby nmaxA is the maximum number of acceptable quality packs from the packaging installation and t is the time unit

NOTE 1 The nominal output is a theoretical value

NOTE 2 Packaging machines which for example can produce several pack sizes have correspondingly several
nominal outputs

NOTE 3 with sequentially linked elements of the packaging installation qnA is equal to the nominal output of the
machine with the lowest nominal output in the packaging installation (bottle neck machine)

NOTE 4 The time unit t can be for example a shift, an hour or a minute

3.2.3.1.2 Target output of a packaging installation qestA

mathematical number of acceptable quality packs (nestA) per time unit which the packaging installation at the
set working speed and with uninterrupted running and disruption free production produces:

nestA
qestA = (25)
t

whereby nestA is the mathematical number of acceptable quality packs from the packaging installation and t is the time
unit

NOTE 1 The nominal output is the upper limiting value for the target output.

NOTE 2 The target output is dependent on the package type and size, the packaging materials and packaging
ancillaries, the product and the system of pack closure

NOTE 3 The time unit t can be for example a shift, an hour or a minute

NOTE 4 With all packaging installations of loose linkage the individual elements of the installation are generally set
to different working speeds. The target output of the packaging installation with sequential linkage is
therefore the same as that of the individual packaging installation element with the lowest target output.
With packaging installations with parallel linkage the target ouput is the same as that of the smallest sum
of the target output of the parallel linked elements of the packaging installation.

NOTE 5 With packaging installations with control over the working speed of the individual installation elements the
working speed can alter according to the process. The target output in this case can not be extracted
through a preset figure but only on the basis of the actual running cycles completed within the period of
observation

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3.2.3.1.3 Operating output of a packaging installation qbtrA

actual number of acceptable quality packs (nbtrA) which are produced by the packaging installation within the
operating time (tbtrA):

nbtrA
qbtrA = (26)
tbtrA

whereby nbtrA is the actual number of acceptable quality packs from the packaging installation and tbtrA is the operating
time (3.1.3.2)

NOTE 1 It takes into account all lost times ( 3.1.9.2)

NOTE 2 It is an empirical value

NOTE 3 By definition is qbtrA < qestA

3.2.3.1.4 Effective output of a packaging installation qeffA

actual number of acceptable quality packs (nbtrA) which are produced by the packaging installation based on
the operating time (tbtrA) after reduction for machine external (tvtfA) and organisationally caused (tvoA) lost
times:

nbtrA
qeffA = (27)
tbtrA − t vtfA − t voA

NOTE The effective output takes into account all the lost times ( 3.1.9.2)

3.2.3.2 Availability of a packaging installation vA

3.2.3.2.1 Total availability of a packaging installation vgA

Relationship of the time in which the packaging installation is producing to an acceptable quality (quality time
tqA) to the operating time (tbtrA) expressed as a percentage:

t qA
v gA = × 100 (28)
t btrA

3.2.3.2.2 Technical availability of a packaging installation vtA

Relationship of the time in which the packaging installation is producing to an acceptable quality ( quality
time tqA) to the operating time (tbtrA) after reduction for the organisationally caused lost times (tvoA) , expressed
as a percentage:

t qA
vtA = × 100 (29)
tbtrA − t voA

3.2.3.3 Efficiency rate of a packaging installation ηA

3.2.3.3.1 Total efficiency rate of a packaging installation ηgA

Relationship of the operating output (qbtrA) to the maximum possible output at the set working speed (target
output qestA) expressed as a percentage:

q btrA
η gA = × 100 (30)
q estA

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 15 -

3.2.3.3.2 Technical efficiency rate of a packaging installation ηtA

Relationship of the operating output (qbtrA) to the target output (qestA) after reduction for restorative losses
occasioned in the organisationally caused lost time (tvoA), expressed as a percentage.

qbtrA
η tA = × 100 (31)
qestA ⋅ (1 − (t voA / tbtrA ) )

3.2.3.3.3 Installation technical efficiency rate ηaA

Relationship of the effective acceptable quality output (qeffA) to the produceable production quantity (qestA) at
the set working speed and with uninterrupted running and disruption free production, expressed as a
percentage:

qeffA
η aA = × 100 (32)
qestA

3.3 Definitions for the structures of packaging installations

The types of installation structures listed below differ in the methodoloy by which the reference factors for the
packaging installations are calculated from the data and reference factors of the individual elements of the
installation.

In order that those packaging installations which perform multi-stage packaging processes have comparibility
of reference factors the number of primary packs produced is taken in these cases as the basis.

3.3.1 Sequential linkage

3.3.1.1 Uncontrolled rigid sequential linkage

Sequential linkage in which the in-line machines and linked elements are directly connected to each other as
part of a material flow process, where there is no buffer effect, where they work with the same operating
method (continuous or discontinuous) and same operating speed and where the working speed is not
controlled.

3.3.1.2 Controlled rigid sequential linkage

Sequential linkage in which the in-line machines and linked elements are directly connected to each other as
part of a material flow process, where there is no buffer effect, where they work with the same operating
method (continuous or discontinuous) and same operating speed and where the working speed is controlled.

3.3.1.3 Uncontrolled loose sequential linkage

Sequential linkage in which the working speed is not controlled and in which one or more of the individual
installation elements within the line have a buffer effect by which the sequentially following machine or
installation sections are decoupled from each other as regards the material flow at that specific time.

3.3.1.4 Controlled loose sequential linkage

Sequential linkage in which the working speed is controlled and in which one or more of the individual
installation elements within the line have a buffer effect by which the sequentially following machine or
installation sections are decoupled from each other as regards the material flow at that specific time.

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 16 -

3.3.2 Parallel linkage of identical elements

3.3.2.1 Uncontrolled parallel linkage of identical elements, without buffer

Parallel linkage where the installations have sections in which the same machines or linked elements are
connected parallel to each other, in which a material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements have the same working speed
which is not controlled and where there is no buffer.

3.3.2.2 Controlled parallel linkage of identical elements, without buffer

Parallel linkage where the installations have sections in which the same machines or linked elements are
connected parallel to each other, in which a material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements have the same working speed
which is controlled and where there is no buffer.

3.3.2.3 Uncontrolled parallel linkage of identical elements, with buffer

Parallel linkage where the installations have sections in which the same machines or linked elements are
connected parallel to each other, in which material flow is split into several channels or several material flow
channels converged into one, where the machines and linked elements have the same working speed which
is not controlled and where within the installation buffers are available.

3.3.2.4 Controlled parallel linkage of identical elements, with buffer

Parallel linkage where the installations have sections in which the same machine or linked elements are
connected parallel to each other, in which the material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements have the same working speed
which is controlled and where within the installation buffers are available.

3.3.3 Parallel linkage of different elements

3.3.3.1 Uncontrolled parallel linkage of different elements, without buffer

Parallel linkage where the installations have sections in which different machines or linked elements are
connected parallel to each other, in which the material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements can work at differing speeds,
which are not controlled, and where there is no buffer.

3.3.3.2 Controlled parallel linkage of different elements, without buffer

Parallel linkage where the installations have sections in which different machines or linked elements are
connected parallel to each other, in which the material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements can work at differing speeds,
which on some or all of the installation elements can be controlled and where there is no buffer.

3.3.3.3 Uncontrolled parallel linkage of different elements, with buffer

Parallel linkage where the installations have sections in which different machines or linked elements are
connected parallel to each other, in which the material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements can work at differing speeds,
which are not controlled, and where within the installation buffers are available

3.3.3.4 Controlled parallel linkage of different elements, with buffer

Parallel linkage where the installations have sections in which different machines or linked elements are
connected parallel to each other, in which the material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements can work at differing speeds,
which on some or all of installation elements can be controlled, and where within the installation buffers are
available.

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 17 -

4 Definition of the reference factors

4.1 Definition of the reference factors for packaging machines

The definition of the reference factors of packaging machines serves as a validation of their performance
capacity. This can, other than by these theoretical reference factors, only be verified in the appropriate
working environment. The verification of the reference factors during machine acceptance or functional
validation must always take place under the agreed conditions appropriate for the application with regard to
machine condition, packaging materials, packaging ancillary materials, product, operating personnel,
production organisation and working environment. During this process the operating time normally begins
when the installation is in stationary operation and ends before the installation is run empty. The compilation
of the data for the definition of the reference factors on the packaging machine can either be carried out
manually or with technical assistence (BDE/MDE). The aim is to ensure that adequate, mutually agreeable
statistical reliabilty of the results is achieved.Apart from the data relating to production and breakdowns it is
also important to record the influences from the operating personnel and the environmental conditions.

Prior to the start of the data acquisition it is always necessary to:

- establish the duration of the observation/investigation time ( = machine working time)

- segregate technically and organisationally the packaging system under review

- establish and define the conditions and circumstances of a breakdown, and

- if a causal analysis is to be made then the allocation of the breakdowns to the cause according to
illustration 1 needs to be made.

4.2 Definition of the reference factors for packaging installations

4.2.1 General

With packaging installations the definition of the reference factors can be made with three possible methods:

a) Data acquisition at the packaging machine installation and calculation of the reference factors from that
data.

b) Calculation of the reference factors from the known data and reference factors from the installation
elements

c) Simulation of the operating process of the installation

For the pursuance of the the differing objectives on which the calculation of the reference factors is based
there are different definition processes which apply. The suitable usage is a follows:

Acquisition: optimisation of the process and installation assessment, machine acceptance, appraisal
Calculation: planning, project management or process optimisation
Simulation: planning, project management, process or installation optimisation.

4.2.2 Data acquisition

Manual or automatic acquisition of the operating and lost data at the packaging installation according to
section 4.1

This method assumes the presence of the packaging installation in a fit for purpose functionality. It demands
mostly a high level of application in terms of personnel and time, but does deliver precise results for the
areas under investigation and is theoretically uncomplicated.The consequent results are not transferable to
other situations.

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 18 -

4.2.3 Calculation

The calculation of the reference factors for the packaging installation from the known data and reference
factors from the installation derives from the basis of approximation process and from the gradual reduction
of the actual installation structure to simplified structures. This method is in practice only really applicable to
very simple structures, eg rigid sequential linkage and uncontrolled parallel linkage of identical elemenst
without buffer, see 3.3.1.1, 3.3.1.2, 3.3.2.1). As the size and complexity of the packaging installation grows
so does the required level of effort grow disproportionally, the results become increasingly unreliable and
there is a large increase in the theoretical demands on the mathematical representation of the installation.
The calculations deliver increasingly median reference factors.

For the following cases the practical calculation is sensible:

a) Uncontrolled and controlled rigid sequential linkage (3.3.1.1, 3.3.1.2):

qnA = (qni ) min (33)

qestA = (qesti ) min (34)

qbtrA = qestA × [1 − ∑ ((tbtr − t v ) / tbtr )i ] (35)

[
qeffA = qestA × 1 − ∑ ((tbtr − t vtf ) / tbtr )i ] (36)

1
v gA = × 100 in %
1 + ∑ (t v / t q )i
(37)

1
vtA = × 100 in % (38)
1 + ∑ (t vt / t q ) i

η gA = Πη gi (39)

ηtA = Πηti (40)

η aA = Πη mi (41)

b) Uncontrolled parallel linkage of identical elements without buffer (3.3.2.1):

qnA = ∑ qni (42)

qestA = ∑ qesti (43)

qbtrA = ∑ qbtri (44)

qeffA = ∑ qeffi (45)

v gA = ∑ (i k ) × v gi × (1 − v gi ) k = 0, 1,..., i − 1
i −k k
(46)

vtA = ∑ ( k )× vti × (1 − vti )k

i i k −
(47)

η gA = ∑ (i k ) × η gi i −k × (1 − η gi )k (48)

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 19 -

 ηtA = ∑ (i k ) × ηti i −k × (1 − ηti )k (49)

η aA = ∑ ( i k ) × η mi i − k × (1 − η mi )k (50)

with k=0,1,....,i-1
i= number of installation elements
k= number of the installation elements out of operation

With all other types of linked installation the calculation method is too imprecise or too laborious and
therefore not possible or practical.

4.2.4 Simulation

For the simulation of the operating performance of the packaging installation a PC with a simulation system
is used to display the target installation and the packaging process is projected as near as possible to
reality.This method is very quick and flexible to changing conditions. The simulation delivers considerable
information over and above the reference factors relating to the performance of the target installation.

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 20 -

 Appendix A (normative)

Table A.1 — Formula symbols

Formula symbols Designation Section
η Efficiency rate of a packaging machine 3.2.2.3
ηA Efficiency rate of a packaging installation 3.2.3.3
ηaA Installation technical efficiency rate 3.2.3.3.3
ηg Total efficiency rate of a packaging machine 3.2.2.3.1
ηgA Total efficiency rate of a packaging installation 3.2.3.3.1
ηm Machine technical efficiency rate 3.2.2.3.3
ηt Technical efficiency rate of a packaging machine 3.2.2.3.2
ηtA Technical efficiency rate of a packaging installation 3.2.3.3.2
naus Number of waste packs from a packaging machine 3.1.7.1
nausA Number of waste packs from a packaging installation 3.1.7.2
nbtr Actual number of acceptable quality packs relating 3.1.8.1
to the operating time of the packaging machine 3.2.2.1.3
nbtrA Actual number of acceptable quality packs relating to the 3.1.8.2
operating time of the packaging installation 3.2.3.1.3
nest Mathematical number of acceptable quality packs 3.2.2.1.2
at a set working speed of the packaging machine
nestA Mathematical number of acceptable quality packs 3.2.3.1.2
at a set working speed of the packaging installation
nle Number of empty cycles 3.1.6.1, 3.1.6.2
nmax Maximum number of acceptable quality packs of a 3.2.2.1.1
packaging machine
nmaxA Maximum number of acceptable quality packs of 3.2.3.1.1
a packaging installation
q Output of a packaging machine 3.2.2.1
qA Output of a packaging installation 3.2.3.1
qbtr Operating output of a packaging machine 3.2.2.1.3
qbtrA Operating output of a packaging installation 3.2.3.1.3
qeff Effective output of a packaging machine 3.2.2.1.5
qeffA Effective output of a packaging installation 3.2.3.1.4
qest Target output of a packaging machine 3.2.2.1.2
qestA Target output of a packaging installation 3.2.3.1.2
ql Running time output of a packaging machine 3.2.2.1.4
qn Nominal rated output of a packaging machine 3.2.2.1.1
qnA Nominal rated output of a packaging installation 3.2.3.1.1

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 21 -

 Table A.1 — (complete)

Formula symbols Designation Section

t Time unit 3.2.2.1.1
ta Breakdown time of a packaging machine 3.1.5.1
taA Breakdown time of a packaging installation 3.1.5.2
taus Waste running time of a packaging machine 3.1.7.1
tausA Waste running time of a packaging installation 3.1.7.2
tbtr Operating time of a packaging machine 3.1.3.1
tbtrA Operating time of a packaging installation 3.1.3.2
tl Running time of a packaging machine 3.1.4.1
tlA Running time of a packaging installation 3.1.4.2
tle Empty running time of a packaging machine 3.1.6.1
tleA Empty running time of a packaging installation 3.1.6.2
tm Machine working time of a packaging machine 3.1.1.1
tmA Machine working time of a packaging installation 3.1.1.2
tneb Downtime of a packaging machine 3.1.2.1
tnebA Downtime of a packaging installation 3.1.2.2
tq Quality time of a packaging machine 3.1.8.1
tqA Quality time of a packaging installation 3.1.8.2
tv Lost time of a packaging machine 3.1.9.1
tvA Lost time of a packaging installation 3.1.9.2
tvo Organisationally caused lost time of a packaging machine 3.1.9.1.2
tvoA Organisationally caused lost time of a packaging 3.1.9.2.2
installation
tvt Technically caused lost time of a packaging machine 3.1.9.1.1
tvtA Technically caused lost time of a packaging installation 3.1.9.2.1
tvtf Machine external, technically caused lost time 3.1.9.1.1.2
tvtfA Installation external, technically caused lost time 3.1.9.2.1.2
tvtm Machine related, technically caused lost time 3.1.9.1.1.1
tvtmA Installation related, technically caused lost time 3.1.9.2.1.1
v Availability of a packaging machine 3.2.2.2
vA Availability of a packaging installation 3.2.3.2
vg Total availability of a packaging machine 3.2.2.2.1
vgA Total availability of a packaging installation 3.2.3.2.1
vm Machine technical availability 3.2.2.2.3
vt Technical availability of a packaging machine 3.2.2.2.2
vtA Technical availability of a packaging installation 3.2.3.2.2

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 22 -

 Appendix B (normative)

Types of linkages of packaging installations

B.1 Sequential linkage

Illustration B.1 – Uncontrolled rigid sequential linkage

Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Packungen Packages

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 23 -

 Illustration B.1.1 – Controlled rigid sequential linkage

Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Packungen Packages

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 24 -

 Illustration B.1.2 – Uncontrolled loose sequential linkage

Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Puffer Buffer
Packungen Packages

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 25 -

 Illustration B.1.3 – Controlled loose sequential linkage

Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Puffer Buffer
Packungen Packages

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 26 -

B.2 Parallel linkage of identical elements

Illustration B.2.1 – Uncontrolled parallel linkage of identical elements without buffer

Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Packungen Packages

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 27 -

 Illustration B.2.2 – Controlled parallel linkage of identical elements without buffer

Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Packungen Packages

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 28 -

 Illustration B.2.3 – Uncontrolled parallel linkage of identical elements with buffer

Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Puffer Buffer
Packungen Packages

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 29 -

 Illustration B.2.4 – Controlled parallel linkage of identical elements with buffer

Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Puffer Buffer
Packungen Packages

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 30 -

B.3 Parallel linkage of different elements

Illustration B.3.1 – Uncontrolled parallel linkage of different elelemnt without buffer

Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Packungen Packages

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 31 -

 Illustration B.3.2 – Controlled parallel linkage of different elements without buffer

Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Packungen Packages

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 32 -

 Illustration B.3.3 – Uncontrolled parallel linkage of different elements with buffer

Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Puffer Buffer
Packungen Packages

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 33 -

 Illustration B.3.4 – Controlled parallel linkage of different elements with buffer

Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Puffer Buffer
Packungen Packages

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 34 -

 Bibliographical references

[1] DIN EN 415-2, Safety of packaging machines - Part 2: Packaging machines for pre-made formstable
packaging materials.

[2] DIN EN 415-3, Safety of packaging machines - Part 3: Form, Fill and Seal machines.

[3] DIN EN 415-4, Safety of packaging machines - Part 4: Palletising and Depalletising equipment.

[4] DIN 8783, Drinks filling equipment - investigate analysis of filling equipment technology.

© VDMA – Packaging Machinery Association (Translation by VDMA 05/2005) - 35 -