Cermex, for comprehensive packaging equipment solutions
Four Wrap Around Case Packers installed at the Australian biscuit producer, Arnott's: Cermex technology travels well!
Global player in end of line packaging machinery, Cermex proposes innovative custom-built solutions to meet every requirement, whatever the project or the field of activity. The most recent remarkable example is the design, build and installation in 2010 of 4 wrap around case packers at Arnott's, an iconic name in the Australian biscuit industry.
André Spoor, Project Engineer for Arnott's, explains that the requirement was to move from manual case packing to automated case packing as well as to change the type of secondary packaging, whilst guaranteeing a quick start-up in production on four lines simultaneously. He also adds that the solution needed to protect the integrity of the products and offer flexibility to accommodate frequent format changeovers and exponential increases in speed. Cermex consequently worked on 2 main axes to meet this challenge: innovative project management and original technical solutions!
The requirements: 5 major challenges
The primary packaging handled consists in rectangular or pyramid-shaped cartons, or flow-packed plastic trays of round biscuits. The project's first challenge involved controlling product conveying and collation, whilst preventing the flowpacks from rotating. The second challenge resided in protecting the product integrity with the capacity to implement gripping systems adapted to 58 different SKU's packed into 32 different case sizes and formats. The third challenge stemmed from Arnott's choice to change secondary packaging (from RSC to wrap around blanks) at the same time as the lines were automated. Speed was the fourth challenge, with a requirement for 12.5 cases per minute and a maximum pack speed of 175 packets per minute. Quick and easy format changeovers were also stipulated in the requirements. According to André Spoor, in charge of the project for Arnott's, the two most crucial aspects were: "The large number of SKUs and the fact that we previously packed our product in RSCs and these all had to be changed to wrap around cases as part of the project."
A fifth challenge comprised the quick integration of the four machines at Arnott's production site. The requirement for immediate reliability was outlined throughout the thought process.
"The project required that we install four machines back to back / concurrently on our four main production lines. Three of the lines have no buffer system prior to the case packer so once installed any downtime on the case packers would have a significant impact on the site's efficiency."
Technical performance meets the challenges set by Arnott’s
Cermex installed in 2010 three identical multi-function WB45 wrap around case packers and one traditional wrap around case packer for a slower line.
An initial series of innovations on the WB45 with product integrity in mind
The first decision was to integrate two robots per machine in order to guarantee operation at the required speed and optimum machine life span. Each robot runs at a reduced nominal speed so that the products do not endure too frequent accelerations and decelerations. Cermex chose robots manufactured by Fanuc, well known in Australia, particularly due to its strong presence in the car industry.
The second key idea consisted in transferring the products 90° onto a collation table by a small Pick & Place module, in order to prevent the flow-packs from rotating. The table is made up of front and rear servo-driven brackets to support the batch.
Robotic gripping and loading encompassed the third key idea: loading is started by robot 1 and finished by robot 2, with smooth movements so that loading can be carried out without using a funnel.
The fourth strong point of the Cermex solution in favour of product integrity is based on the gripping tooling: the heads are composed of 30 to 50 mini suction cups, so as to constantly maintain the vacuum gripping even if one of the suction cups loses its adherence with the product. This is very important for flow-packs, as gripping film is tricky.
A second series of innovations to meet flexibility requirements
Robotics contributed to simplifying the solution and reducing the number of parts and adjustments so that the Cermex WB45 could fully meet Arnott's requirements. In particular, the robot tooling common to several formats, helps to significantly reduce the changeover time in order to achieve 25 minutes maximum.
The absence of multi-lane guides on the product infeed also reduces setting requirements. Furthermore, the robot heads all weigh less than a kilo; a reduced mass which considerably facilitates changeover.
For Arnott’s, there is no doubt that flexibility is a key factor of success "Our company is continually looking to develop new products. The ease of setting up new products ourselves with minimal requirements for new change parts and the flexibility in the machine to pack different case formats is important. It was for this reason that we chose a robotic solution for three of the four case packers."
Close follow-up essential to a hitch-free start-up
Cermex's ability to accommodate Arnott's requirements throughout the project
In addition to the existing Cermex installed base in Australia, the permanent presence of a team of engineers from Cermex Sales & Services in Bangkok, the Cermex local representative in Sydney and the support given directly from Cermex France created the intimacy that was necessary to successfully complete this project that was ambitious both in terms of technical solution and lead time.
Cermex contract management was perfectly adapted to the context:
- in its capacity to smoothly integrate the changes in technical data which intervened throughout the project
- thanks to mutual collaboration: joint design and optimisation
- by routine vigilance in meeting lead times and production constraints.
This was evident to Arnott’s: "Cermex willingness to listen and to respond to the needs on our site and to adapt the machine solution to changes within our business throughout the design, build, install and commissioning of the machines."
Technical expertise measuring up to the stakes of the contract
By choosing Cermex, Arnott's could rely on packaging line expertise. On the one hand, the complexity and multiplicity of the challenges required project management commensurate with the global dimension of Cermex. On the other hand, it was vital to be able to count on a Design Office experienced in extraordinary challenges in order to find the most suitable solution, in particular in terms of layout. The 3D simulation of the various technical options envisaged made it possible to arrive quickly and with minimum resources at the optimal solution chosen. The broad expertise of Cermex in robotics and numerous recent references in this field, such as Veuve Clicquot Ponsardin (Champagne) or Celtigel (food), gave extra credit to the concepts proposed.
Arnott’s is pleased with its choice: "This project was a significant challenge for the site that required much cooperation and patience from our operators and a high level of flexibility from the Cermex commissioning engineers. We are proud that the team found a way to deliver on that challenge and work together through a significant period of increased activity and stress that was placed on the site".
Initial feedback positive
In accordance with the requirement formulated by Arnott's from the beginning, Cermex delivered, installed and commissioned four machines. Together, Arnott’s and Cermex devised an install and commissioning methodology that allowed hand packing production to continue throughout the integration of the case packers on Arnott’s site.
As André Spoor sums up "All projects have a finite life whereas maintaining and operating a machine is an ongoing event that continues for the complete life of the machine. During the project we were well supported by Cermex. As we look to maintain and further develop the machine capabilities for new products in the future, it has been pleasing to see that this support has not diminished after the commissioning and sign off of the machines."
Arnott’s, No. 1 biscuit manufacturer in Australia
Arnott's has 3 manufacturing sites in Australia with robotic production lines. It is one of the largest food companies in the Asia Pacific region, with continuous development and extension of its ranges of biscuits and savoury snacks.
Founded 145 years ago, Arnott's employs around 2 600 people in Australia, federated by a very strong commitment towards supporting social and environmental projects.
Exporting its biscuits, including the famous Tim Tam, to more than 40 countries, Arnott's has invested more than 350 million Australian dollars (i.e. 240 million euros) in modernising its manufacturing facilities since 1997.
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