[Case study] Design of a top load case packer for 4 corners glued cases
Context
Our client wanted to automate the case packing and palletizing of one of its high-speed production lines for overwrapped "crème brûlée" pots. The goal was to increase productivity by packaging glass pots in sleeves in various cardboard formats. The client was looking for robust and repeatable equipment to minimize format loading time and increase productivity, as well as a machine that was easy for operators to use.
Product specifications:
- Overwrapped glass pots with compact cardboard sleeves
- 3 product formats (packaged in one or two pots)
- 8 cardboard formats with 4 glued corners
- Packaging by 3 to 12 packs with 10 case-filling recipes
The objectives are multiple and aim to optimize both the production line's performance and operator working conditions:
- Increase line productivity by improving each packaging step
- Enable ergonomic manual case-filling of special productions
- Improve operator working conditions and reduce the risk of musculoskeletal disorders (MSDs).
- Facilitate and accelerate format changeovers
- Enable gradual installation of equipment, using a phased approach adapted to site constraints.
Solution proposed and provided by MG Tech
Initially, we kept the existing case erector, which is located upstream of the top-load case packer we installed at the customer's premises. In the future, the case erector will be replaced by a modern case erector with simplified format changeovers.
We designed a top-load case packer with an infeed rater to case multiple packs simultaneously using two Delta robots. These robots take 1 to 3 packs of products and ensure their case placement in 4-corner glued cases. The cadencer is adjusted according to production and product format.
Top-load case packer rate:
- Maximum product rate: 180 products/min
- Maximum case rate: 45 cases/min
Advantages of the solution:
Product delivery is ensured by a timing system that allows for a regular and controlled flow of 1 to 3 products to the case packer. This process is followed by continuous case packing of the products and cases, ensuring optimal packaging rate and consistent efficiency.
The case packer is distinguished by its compactness, facilitating its integration into an industrial environment with limited space constraints. It is designed to be compatible with the client's current production line equipment. A phased installation is possible to limit the impact on ongoing production and allow for gradual commissioning. At the case packer exit, an ergonomic manual case packer station was designed to provide a comfortable grip for operators and can also be used in degraded mode, thus ensuring business continuity if necessary.
Why did the client choose MG Tech?
The proposed solution is technically and economically relevant and meets all of our client's specifications.
The ergonomics of the proposed machine allow for easy handling by operators thanks to its intuitive HMI screen.
Operator and maintenance technician training is provided by our teams, who also monitor production upon installation startup.