Cermex, for comprehensive packaging equipment solutions
Compact Combined Side-Loading Case-Packing, Labeling and Palletizing Unit for Cosmetics
In developing this case packing and palletizing unit combining the brand new SW23 case packer with a Fanuc 6-axis palletizing robot, Cermex delivers a high-performance complete solution for one of the American plants of a world leader in the cosmetics industry. This innovative solution meets this sector’s demanding requirement for compact layouts whilst integrating additional functions such as labeling. Commissioning is scheduled for the end of 2008.
Condensing and integrating complementary machines into the same unit constitutes a development in itself, but it does not end there.
A modern end of line cannot sacrifice operator ergonomics and efficiency, even and above all in the quest for a reduced layout!
This new development, engineered by Cermex’s Design Office (120 people out of a total staff of 500) in collaboration with the project team based in its US subsidiary in Atlanta, is consequently remarkable in more ways than one.
A perfectly-mastered general principle of case packing/palletizing units!
In addition to its general expertise in end of line solutions acquired since its creation in 1974, Cermex has become an expert in the specific development of case packing and palletizing units with 12 years’ experience initiated by the success of the EP range.
With this new development, Cermex paves the way to units combining functions derived from very distinct machines:
- side-loading case packing with the SW23 model from the Cermex range
- case handling and palletization by integrating and programming a polyarticulated 6-axis Fanuc robot
With this functional combination of modules (1 module = 1 main function) grouped into a single unit, Cermex goes beyond the historical principle of multi-function monobloc units whose limits lie in the considerable number of functions borne by a single main organ (even when it is a robot) which restricts the possibilities for evolution.
In the unit presented here, the flow starts with the collation of individual products for which the primary packaging is a carton. The products are then loaded into the RSC by the multi-function SW23 side-loading case packer. At the outfeed of this module, the cases are immediately labeled by the M710 iC palletizing robot which also controls the correct presence of the label by passing the case in front of a scanner, then palletizes the case if the operation is validated.
A concentration of technology and ergonomics in less than 13 m² for side-loading case packing
The SW23 with its exclusive patented case extraction system contributes considerably to the industry’s essential requirement to reduce the layout of production and packaging equipment. Consequently, its dual extraction arm is composed of a set of articulations following a trajectory which brings it back as close as possible to the magazine while extraction/opening the case. This movement, so innovative and efficient in saving space, is servo-driven and patented. The extracted and formed case is then held at the loading station behind which the cartons have been previously collated by an elevating stacking system. A servo-driven pusher then safely transfers the product batch into the open RSC thanks to a mobile loading funnel principle to guide the operation. This loading funnel guarantees the integrity of the carton covering during the loading phase: the quality of functions provided is not sacrificed in the quest for a compact footprint!
The case is then transferred by a servo-driven shuttle to the flap folding and taping stations. The customer opted for the adhesive tape technique rather than sealing with hot-melt glue. This was achieved without increasing the footprint. Morevoer, to offer maximum ergonomics without impacting volume, the Cermex engineers positioned the adhesive tape supports on the front side of the machine making refilling easier for the operator.
In addition, the whole of the SW23 frame follows clean design principles.
- total accessibility, the operator is not required to step over any structural elements
- encasing of lower elements to ensure products do not become lodged inside
- TPM design (Total Production Maintenance), etc…
A concentration of multi-functions in less than 13m² for the palletization
At the case packer outfeed, the robot grips the case by means of suction cup tooling, turns it upright and presents it in front of the labeler to guarantee perfect tracking. The Fanuc 6-axis robot then passes the case in front of a laser scanner so as to immediately control the correct printing and application of the label. If the control is positive, the robot can then palletize the case according to the pallet pattern selected by the operator. Otherwise, the case is placed on a specific rejection conveyor in order to be rehandled...
In addition to preserved ergonomics and the functional quality, Cermex took on the challenge to optimise the machine cycles of this case packing and palletizing unit, as proven by the pallet oufteed procedure.
When a pallet is finished, the operator can remove it safely by means of an automatic mobile partition giving access to the unit. A multi-beam safety curtain isolates the active zone from the dormant zone. During this time, the robot continues to work at a distance from the operator and thanks to its working envelope and programming, it positions the labeled cases which continue to be produced on a specially adapted rack near the SW23 case packer.
Consequently, as soon as the empty pallet is available, the robot first starts by taking the cases from the buffer stock before continuing its normal cycle downstream from the case packer/labeler...
This compact unit therefore works continuously, without disrupting the upstream elements.
An extremely versatile solution to begin a new saga!
From the start of commercial consultations on this project, Cermex’s customer particularly appreciated the option of handling both pre-joined RSC and wrap around blanks on the SW23 side-loading case packer. Even if the current specification does not require this versatility, being able to integrate such a machine into a case packing module is a true success factor for the Cermex team. In the same way, the choice of a 6-axis robot for the palletization is justified by the working envelope available and consequently its capacity to handle the cases at different stages in the cycle. The combination of two such powerful and versatile machines while remaining flexible in the size range is indeed the crucial factor in the unit’s development.
This particularly successful application demonstrates Cermex’s global expertise:
- as a multi-technology specialist, offering a wide range of solutions from which the compact SW23 side-loading case packer is derived
- as an integrator of outsourced equipment such as the Fanuc 6-axis robot and the labeling equipment
- as a developer of original concepts such as this one
This American example has inspired a second application for another factory for the same customer, based in France this time, which will shortly see a robot carrying out the top-loading case packing (and not side-loading as with the above example), in a case-handling module derived from the range of SD case packers. The robot then executes the same cycle as presented above (labeling, control, palletization)...
When a concept is so quickly adapted from one requirement to another, it’s a technological and commercial sign which heralds numerous references for the manufacturer!
Main characteristics:
Market sector:
- Cosmetics industry at low speeds
- Rectangular cardboard cartons, to be collated flat (products upright in the outer)
- RSC and, if required in the future, wrap around blanks
- Product infeed speed of the application: 22 products/min
- SW23 side-loading case packer outfeed speed: 1 case formed, loaded and taped per minute
- Overall outfeed speed of the unit (case packing + palletization): 3.5 cases/min
- Characteristics of the M710 iC 70 palletizing robot for this application: maximum payload of 70kg for a radius of 2.05 meters
- A single control interface for all the machines