Other applications
Packing machine for boxes and trays
Packing primary packed products in carboard boxes, display trays or crates is a process that generally can be automated. By deploying robots to accomplish this task, one obtains a highly flexible solution resulting in several packing patterns and fast product changes being possible. Stacking of full boxes by a portal robot has the same advantages. The setup requires little space and pallets can be stacked to a great height. An additional advantage is that the robot can stack several production lines simultaneously on individual pallets.
NACE code
06.10
10.31
10.52
10.71
10.72
10.82
10.83
10.89
10.91
20.15
20.59
21.20
32.50
49.41
52.10
Specific industry knowledge
Food
Automatic Case Packing
More information regarding the deployment of SPIDER ROBOTS for Automatic Case Packing specifically for boxes & trays will follow soon.
By deploying robots to automate a packing process one obtains a highly flexible solution resulting in several packing patterns and fast production changes being possible. Moreover, Delta robots and Cartesian robots have the advantage of taking up little space. When packing non-dimensionally stable products they are picked individually at high feed speeds. Dimensionally stable products are preformed into rows and layers before being packed.
The SPIDER Case Packer comes in two versions. The version with a Delta robot uses a unique product recognition system that detects the position and rotation angle of a product on the infeed conveyor. This information is transmitted to the Delta robot that picks the product * “in the flight” and packs it in the box, crate or tray. Several Delta robots can be used in the event of extremely high supply speeds. This packing method is especially suitable for packing bags. With the version with a Cartesian robot, the products waiting to be packed are preformed into rows or layers after which they are picked up for packing. At high feed rates several boxes, crates or trays can be filled simultaneously.
Bottles, cans, flasks or jars are pre-sorted via a divider into the desired rows after which they are picked up for packing. Boxes and other dimensionally stable products are pre-sorted per row and transferred onto a diagonal supply belt * dwarse taktband to the required number of rows, before being picked and packed. In the case of several layers in the box, the cycle is repeated. A funnel * trechter keep the box’s flaps open while the layers are being introduced.
Bags and other non-dimensionally stable products are picked up one by one depending on their position on the infeed conveyor. Their position is detected by a patented vision system that is both colour and reflection-independent. At high feed rates, the robot picks two products one after the other before laying them individually or per two in the box. Several robots can even be setup where the boxes are partially filled by each robot. A servo-driven box-changing system guarantees extremely fast implementation of box changes.
Thanks to the unique gripper fast-change system and also that new packing patterns are easily set up by yourself, a great many products with their specific packing pattern can be handled. This means that a setup with the SPIDER Case Packer is extremely flexible and ensures that future products will also be able to be handled.
As a rule, check weighers for the primary packed products and filled boxes as well as metal detectors are part of a case packing project. Various box formers and sealers are also used for the handling of boxes or trays.
Specific industry knowledge
Chemical
Pharma
Food (Chocolate)
Energy (Oil & gas)
Food (Bakery & yeast)
Logistics & storage
Food (Coffee & tea)
Food (potatoes)
Food (Ice cream)
Medical
Automatic Palletizing
Automatic palletising of boxes
The cardboard box is the most common product to be palletised. Various grippers are used depending on the type of box or tray. American boxes are usually picked up by a vacuum gripper. Palletising is done by picking up the boxes per one, two per row or even per complete layer, resulting in high feed speeds being achieved. The boxes are deposited separately, per row or per layer, depending on the stacking pattern.
Whenever a vacuum gripper is unsuitable, a clamp gripper is used. In the case of lidded boxes, we ensure that the lid cannot come loose from the box while the gripper rises. Similar boxes are palletised individually or per row.
For palletising boxes there are also grippers available that partially or fully support the boxes from underneath. This is vital when the boxes have no natural sturdiness or when the contents of an open tray don’t allow any clamping. Automatic gripper settings are applied when a gripper change is not required when switching to another product. The grippers can also handle cardboard interleaves, sheets of paper or foil that are automatically laid between the layers. These are always inserted during box palletisation.
Product changes
There are two possibilities for product changes: either one opts for an all-in-one gripper so that a gripper change is unnecessary or the grippers are changed via the unique quick-change system which takes no time at all.
For unstable loads, a semi-automatic or fully automatic pallet wrapper can be integrated into the Spider. During the palletising of the boxes the pallet is simultaneously wrapped. After one or two layers have been stacked, they are automatically wrapped and then stacking continues. At the end of the cycle, the wrapping cycle is completed and the pallet can be removed.
Destacking
The Spider portal robot can also be used for destacking boxes for among other things putting together orders. For this, use is made of vision systems or unique software that “searches” for the boxes on the pallet. De destacked boxes are usually coded during processing before being stacked again.
Types of boxes and trays
– American boxes
– boxes with loose lids
– open trays
– low trays with jars
– display boxes
– boxes with U-shaped cardboard lids
– bag-in-box boxes
– boxes holding flat-pack furniture
Specific industry knowledge
Feed
Food (coffee & tea)
Food (ice cream)
Agro
Total End-Of-Line Automation
Many companies prefer to have their entire end-of-line automation come from a single manufacturer. This is exactly what we can offer since, besides the SPIDER Case Packer and the SPIDER Palletiser, we also integrate diverse peripheral equipment. Check weighers, metal detectors, empty and full pallet handling, pallet wrappers and pallet labellers are built together with the packing and stacking robots to form a single line where all individual components are coordinated. The line in its entirety is setup beforehand in our workshop and fully tested using the customer’s products.
Various box and tray formers, crate de-stackers and blister denesters are used to feed the empty secondary packaging to the SPIDER Case Packer. The setup is such that the supply of packing material can run optimally.
The SPIDER Case Packer is setup in such a way that everything is easily accessible and that gripper changes can be implemented quickly. If desired, a separate manipulator is provided to place leaflets or booklets automatically in the box.
The fully-filled boxes, trays or crates are either weighed or their contents is controlled via a vision system to ensure that all products have been packed. A reject is on hand to ensure that incompletely filled boxes, trays or crates are not accepted so that production does not have to be stopped in the event of a partially-filled box.
Various box sealers and lid placers are integrated into the line to seal the box after passing weight control.
A box labeller or ink jet is often used to ensure the necessary identification on the box. If required, a barcode scanner controls whether the barcode is legible. If not, the box is rejected.
After this, full boxes, trays or crates are fed to the Spider Palletizer. Various grippers can be on hand for the picking up of sealed boxes, open trays, boxes with lids and crates. All-in-one grippers can also be provided that can stack various packaging. Moreover, the grippers can be additionally fitted with a device to take interleaves, foil sheets and empty pallets.
One of the main benefits of using the SPIDER Palletiser is that, at lower speeds, several lines can be simultaneously stacked by the same robot on individual pallets. Indeed, the Spider is a “portal robot” allowing the frame to have an extra-long extension so that all the pallets can be stacked neatly alongside each other. This also makes it possible to have a simple central supply and removal of empty and full pallets. The full pallets can be removed via pallet transport conveyers, a transfer cart on rails or a portal transfer cart. The latter has the advantage of making obstacle-free passage possible for the transfer cart’s journey.
Various automatic pallet wrappers can also be provided to wrap the full pallets. If required, a cover sheet can be laid on the pallet load resulting in dust-free or waterproof packaging.
Following this, one or several pallet labels can be affixed to the full pallet. The palletising data can be supplemented with additional customer-related information which is then sent to the automatic pallet labeller.
After labelling, the full pallets are taken away and, if required, buffered on a pallet transport conveyor.
our methodology
Analysis
We always start from the existing production environment. You receive a layout, a carefully detailed pricing and a concise description of the solution. We always substantiate our proposal with information on projects already completed in the sector in which you are active.
Project planning
We draw up a project dossier with all the technical details of your installation. We then go through everything together, adjusting and validating the proposal wherever might be necessary.
3D design
Following the validation of the project dossier, we come to a final technical layout. We then convert this into a technical 3D design, giving you a correct image of what your installation will look like.
Line control
In this step the components of your installation are manufactured and we proceed to the development of the line control. All components are connected in a line-by-line fashion with each other so that they are in constant communication with each other.
Assembly line including all peripheral equipment
The complete assembly of your installation, including all peripheral equipment such as weighers, labellers, etc. is done by us in advance. We assemble the complete line with the greatest care into a single unit using a standardised methodology. Because the entire line has been fully operationally tested beforehand, both installation and the further start-up takes no time at all.
FAT
Following the assembly of your installation, it is then extensively tested in our workshops, allowing you to see it at work before being assembled at your premises. Using a comprehensive checklist, the installation is checked down to the smallest detail as to whether it meets all specifications before being transported to you.
Transport, assembly, start-up and training
All components are disassembled before being transported and assembled on site. Your employees are then trained to be able to work optimally with your new installation.
After sales service
At SPIDER we provide an excellent after-sales service. On the one hand, there is the continuous monitoring and logging of your installation so that we can remotely follow the operation in real time via cameras inside the installation, allowing us to make adjustments remotely. On the other hand, you can also call on our experienced service team 24/7.
Reliable partner
We attach great importance to across-the-board communication with our customers. Even before the initial design stage, we want to fully understand their requirements so that we can provide the right end-of-line solution. We build our SPIDER Case Packer and SPIDER Palletiser, as well as their integration, into the complete line. This results in the operator having being able to handle it comprehensibly because of the uniform manner of operation of the various parts. Thorough training is provided for the operators. This is backed by structured after-sales service that the customer can call on 24/7.
Automatic Case Packing
Automatic Palletizing
Total End-Of-Line Automation
