Metzingen. A new product and consulting service offer by Storopack makes it possible to supply a sensor-controlled machine with up to 24 packaging stations using air-cushions. Employees remove the cushions from the silos, which are placed in an ergonomically favourable position for use. The new machine model, the Airplus BagSeparator, already divides the padding strips into sections of the desired length. The packers only have to separate individual air-cushions in about five percent of cases. In practical tests, up to ten cartons per minute were processed using this partial automation.
In order to achieve and maintain a constant high level of output, it is necessary in the opinion of the company to look at the work place layout and the job ergonomics more closely. These two aspects hold a high potential for increased productivity. Storopack integrates this task into the concept of “working comfort” and makes it a part of the consulting approach.
Advisers from Storopack gather details of the needs of the customer and examine the local conditions. Based on this, an optimal spatial arrangement and efficient operational processes are developed. The result is a solution, which fits best in the performance environment of current, automated distribution logistics. The technical prerequisites for this offering from Storopack are the new Airplus BagSeparator for production of air-cushions and a customised programmed control module. The latter controls the production of the cushions and their distribution into the silos via a flat conductor with electrically propelled flaps.
The Airplus BagSeparator system processes all film formats available from Storopack. The running speed is up to 10.5 m/minute. This corresponds to approx. 400 standard cartons each with 8.5 litres of filling material per hour with an air-cushion format of 200 x 120 mm. Important parameters can be adapted during the operation to meet current needs. In addition, the length of the individual padding strips is also important, and can be freely selected from between 1 and 99 cushions.
The machine is suitable both for equipping single place solutions as well as for supplying more than one packing station. Work is organised either inline, i.e. using a conveyor belt-like system, or at off-line packing tables. In order to supply several places, the Airplus BagSeparator feeds air-cushions to a flat channel. Flaps in the channel control the supply to the outgoing silos. A sensor in the silo gives the filling level as information to a programmable controller. This adjusts the status of the flaps. The system takes priorities into consideration, so that individual packing stations are preferentially supplied, if necessary. In order to meet higher demands with so-called speed lines, several devices can supply a single silo.
The kind of silo construction used depends on the spatial possibilities. Free-standing, self-supporting models are nearly always used. The access openings are arranged so that they make sense individually and ergonomically for the packers. In off-line procedures, so-called packing islands have proven an optimal form of organisation for workplaces: Two or four packing stations, in both cases facing one another, are placed on either side of the conveyor.
With the optimal calibration of all components, any manual work which is required at the packing station can be reduced to a minimum. Employees place a delivery note or other shipping documents on top of the goods, as necessary. They take air cushions out of the silo and fill cavities in the package before the cartons are automatically or manually closed.
This customised equipment can be rented or purchased. As the plant is of a modular design, it can be easily adapted to any changes in the circumstances at the logistics centre of the customer. Delivery takes place within six weeks after the order is placed. The installation can normally be assembled within 24 hours.