Client Overview
A leading food manufacturer and producer of iconic breakfast cereal, Weet-Bix, operates multiple high-speed packaging lines where hygiene, precision, and reliability are paramount. Any improvement in motion performance directly impacts production throughput and operational cost.
The Challenge
A critical point in the packaging process in their Australian manufacturing facility involved rapid and repetitive motion to align, fill, and seal cartons. A scenario common across New Zealand's food processing and FMCG packaging facilities. The legacy system used pneumatic actuators, which presented increasing limitations:
- Rising compressed air costs and inefficiencies in energy use
- High maintenance requirements, including worn seals and leaking valves
- Inconsistent motion control, particularly at higher cycle speeds
- Limited hygiene compliance for clean-in-place washdown environments
Throughput was capped at approximately 20 packages per minute due to the speed and control limitations of the pneumatic actuators. The client sought a more efficient, food-grade solution that would also reduce downtime and long-term service costs.
The Powerbox Solution
Powerbox (M.Rutty & Co) supplied the Dunkermotoren ServoLinear SL 38 STL, a stainless steel IP69K-rated linear servo actuator designed specifically for food and beverage environments.
Key features included:
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Fully integrated servo drive, allowing high-speed and high-precision linear motion
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Programmable stroke, speed, and acceleration profiles, eliminating mechanical impact and improving smoothness
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Stainless steel hygienic construction, compliant with washdown and HACCP requirements
- Compact, modular footprint, enabling direct retrofit into the pneumatic cylinder's space
Results and Measurable Gains
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Increased throughput: The system now runs at 30 packages per minute, a 50% increase over the previous pneumatic setup
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Improved efficiency: With no compressed air system, overall energy consumption was reduced
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Reduced maintenance: The sealed linear actuator eliminated failure points such as air lines, valves and seals
- Better motion control: Acceleration and deceleration were tuned for softer stops, less mechanical stress, and smoother handling of packaging materials
- Improved hygiene: The stainless-steel body allows frequent washdown without risk of water ingress or corrosion
A First in Production Deployment
This project marked the first-ever live production use of the ServoLinear SL 38 STL, globally. Following its successful implementation, Dunkermotoren has seen growing adoption of this technology across international food and pharmaceutical packaging lines — with this Australasian site providing the benchmark performance data now referenced by manufacturers worldwide, including those across New Zealand and the Pacific region.
Why Dunkermotoren + Powerbox?
Dunkermotoren's ServoLinear SL 38 STL combines clean, compact design with exceptional performance. With local application engineering and support from Powerbox, the transition from pneumatics to smart linear actuation delivered measurable production gains, reduced service costs, and ensured compliance with the stringent demands hygiene and food safety standards required across Australia & New Zealand's food and beverage industry.
Looking to replace pneumatics or improve motion control in your F+B production environment?
Whether you're processing dairy, meat, seafood, or packaged goods, servo-driven linear motion offers a proven, food-grade alternative to ageing pneumatic systems. Get in touch with the Powerbox Pacific team to find out how we can support your next automation project.
About the Author
James Rutty, Director, Powerbox Australia
James Rutty is a Director at Powerbox Australia, with over 15 years of experience in power electronics for critical infrastructure across Australia and New Zealand. He works with engineers, consultants, and integrators at the architecture level, from initial load assessment and system design through to product specification, commissioning support, and lifecycle management.
