Case Study: Optima Machinery Corporation achieves up to 50% faster changeovers with Rockwell Automation iTRAK

iTRAK Helps Machine Builder Slash Changeover Times By Up To 50%

Optima Machinery Corporation needed a more flexible, agile packaging solution to meet customer demand for varied nonwoven product formats and faster changeovers. Using a Rockwell Automation Integrated Architecture solution, including the iTRAK Intelligent Track System, Optima aimed to replace a belt-based system that required frequent mechanical adjustments and created cumulative downtime during multiple changeovers per shift.

Rockwell Automation implemented an Integrated Architecture solution with Allen-Bradley ControlLogix PAC, iTRAK, Kinetix 6000 servo drives, and PanelView Plus 7 HMI. The new machine cut format changeover time by up to 50%—about 15 minutes per change—improved OEE, increased flexibility for product variation, and reduced operator intervention. Intigena also achieved throughput of up to 1,600 products per minute, with commissioning accelerated on the second line to just one week.

Optima Machinery Corporation

Oliver Rebstock

Managing Director