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Conveyor Types

Flexible and efficient: automated line changeovers for the InnoPET TriBlock from KHS

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Up to 70% time saved compared to manual changeovers / Molds changed by robots on the stretch blow molding module / Automated adaptation to the label gluing height and bottle diameter

The example of KHS’ InnoPET TriBlock stretch blow molder/labeler/filler block illustrates how automated format changeovers can be successfully implemented. And it shows that beverage producers can combine maximum flexibility with a high level of efficiency.

PET lines today are very rarely configured exclusively from individual machines. Instead, beverage producers want a turnkey system with a small footprint, shorter conveying segments and a reduced maintenance effort and – first and foremost – short changeover times. As part of the holistic, automated line changeovers on its PET lines the InnoPET stretch blow molder, labeler and filler TriBlock satisfies these high demands. Thanks to the new KHS InnoPET iflex automation concept beverage bottlers can now save up to 70% of the time needed for manual changeovers. To this end, various functions were developed for the different segments on the InnoPET TriBlock that considerably increase the level of automation and make manual intervention largely superfluous with a few clicks on the HMI.

Format changeovers by robot

PET bottles are produced in the stretch blow molding module. When formats are scheduled for a changeover, the iflex first triggers the automatic loading of recipes for the heating profile, blow pressure, preform conveying and inspection technology.

The most important new feature on this machine is the mold changeover when the new batch requires a different bottle size or shape. Here, the switch is made with the help of a robot that changes the two side mold shells and base mold fully automatically and very quickly during ongoing production. It removes the previous molds from the stations, places them in the mold set magazine, takes out the new molds and slots them back into the stations without any need for action from the operator. The robot needs just 41 seconds per station for this short, fully reproducible procedure. The time for manual intervention is thus reduced from a previous 95 to just eight minutes. This is further facilitated by automatic bottle base detection adjustment at the blow wheel transfer star with the help of several sensors. All the operator has to do by hand is to start the format changeover and later start the new production run.

Less manual intervention

The time and effort needed for manual work by the operator is also reduced in the labeling module. This is chiefly thanks to automatic adaptation of the label gluing height and bottle diameter. The operator still carries out the toolless changeover of the vacuum drum, brushes and bottle guide parts, however. Nevertheless, two labeling stations can now be converted within 20 minutes.

At the press of a button

In the filler module conversion is fully automatic. Firstly, this avoids handling errors by the operator, and secondly, it prevents the risk of bacterial or microbiological contamination by people entering the hygiene area that would then need foam cleaning. This would delay the changeover by around 30 minutes.

The key components relevant to automatic changeovers are the guides from the filler infeed to the capper discharge that need to be set to the bottle diameter and height. Conical base guides or bottle pockets are used here, for example, where the containers are fixed by simple height adjustment as in a funnel. The discharge conveyor is vertically adjusted by a servomotor instead of being manually cranked; the same goes for the horizontal adjustment of the railings. What’s more, the bottle caps are also changed over automatically, such as when a new beverage features a different cap color from the previous one.

Up to 70% quicker

We can see just how important the new iflex options are on the KHS InnoPET TriBlock in particular when it comes to highly flexible beverage filling if we take a look at the total time saving: depending on the specific changeover routine on site, this amounts to approximately 95 minutes. The remaining manual tasks only take eight minutes on the stretch blow molding module and 20 minutes on the labeling module. On the filling module format changeovers have been fully automated and are completed without intervention in a matter of seconds. All told, changeovers are now implemented in less than a third of the time previously required, allowing beverage producers to look forward to a high degree of flexibility and efficiency.

Innoline Flex Control: everything under control

The Innoline Flex Control line management system is essential if the iflex is to function properly and its potential be fully exploited. It takes over the tasks of line and order management from the beverage producer’s ERP system and orchestrates the automatic changeover of the machines. The basic idea is to help the operator to always do exactly the right thing.

By integrating the Innoline Flex Control web GUI into the HMI, data is displayed on the machine operator panel. The operator sees which processing program must be selected when and which materials are needed where to produce the respective current version of the order sequence that has been tactically planned by the system. With the automated iflex variant, this is triggered by the simple press of a button. On the guided iflex version the system clearly prompts the operator through the various steps and provides straightforward instructions for all action that needs to be taken manually.

 

Conveyor Types

Wiggle eCommerce Fulfilment Centre

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Wiggle eCommerce Fulfilment Centre

Conveyor Systems Ltd completed a major installation supplying an extensive pack and sortation conveyor solution for global online retailer Wiggle Ltd. Operating as the UK’s #1 online Cycle, Run & Swim retailer along with being recently voted the Which? recom- mended #1 online outdoor & leisure shop. In 2015, due to the continuous growth of the business, they took the decision to relocate the Operation to a larger, consolidated Fulfilment Centre (320,000 sq.ft.) in the West Midlands from the multiple small sites operated in Portsmouth.

After a rigorous tender process, CSL’s ability to provide a well demonstrated solution was key to meeting the brief and winning the contract. This included using the latest 3D CAD drawing software to help visualise the system as a lifelike operational representation in the new building.

The brief was to combine packed consignments from 3 pick/pack areas over 3 floors and sort them down 12 lanes into 4 dispatch zones for separate carriers and services. The system needed to cope with up to 90 boxes per minute of varying sizes and weights, from very small parts and clothing up to large boxes of bicycle wheels!

The conveyor system which was specially designed by CSL at over 900mm wide, was engineered in detail after taking into account all comments/ suggestions made by both management and operators at Wiggle together with fully recognising their requirements, considering the vast array of shapes and sizes of products whilst overcoming operational issues.

The mezzanine consists of 2 upper floors which along with the ground floor form three independent pick/pack zones and sortation areas which were designed specifically to avoid issues caused when one combined system is stopped for maintenance/Repairs.

Once an order is picked, packing operatives check the order then pack into an array of outers ranging from poly bags to large cardboard boxes prior to applying carrier despatch labels. The consignment is then placed on a section of zero line pressure (ZLP) accumulation roller conveyor which starts the transit to the sortation area on the ground floor. This type of conveyor is used widely on the system to ensure noncontact queuing due to the wide variety of sizes, shapes and weights causing damage to each other and potentially initiating jams along the system.

The upper mezzanine floors use 2 powered Ambaflex spiral lowerators (almost 100 units supplied by CSL throughout the UK to different customers), to safely and continuously bring the boxes down where they are then barcode scanned to determine, by way of state-of-the-art scanning arrays on each line, which carrier despatch lane they require. When the packages reach the correct despatch lane they are diverted off at 90 degrees using high speed switch sorters. Depending on the source pick floor, they either decline down a grip top belt to an ergonomic picking height or transit on a horizontal roller conveyor to the discharge area where a despatch operative removes and places them onto a pallet or into a wheeled cage ready for carrier collection.

CSL provided the full turnkey conveyor project including control, installation and commissioning of the wide range of packages.

“As this was a new facility it was difficult to visualise the conveyor system prior to the mezzanine floor installation, but CSL provided a detailed 3D drawing which included both the mezzanine and the conveyors which brought clarity to this. The install process was smooth and the end results have allowed us to increase control, flexibility & volumes”

Dan Corrigan, Head of Logistics & Operations Development

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Conveyor Types

New, aesthetic Conveying System for the future

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The young Swiss startup Avancon SA (www.avancon.com) has set itself the goal to revolutionize the unit handling systems in distribution and logistics centers. They offer now a new modern and very innovative conveying system. This will be distributed worldwide by manufacturers of conveyor systems and logistic system integrators. The system has been developed by Dieter Specht, the founder of the Interroll Group.The car industry, the computer industryand even the machine industry presentevery few years new and moderndesigned models. Why? To be able toattack new markets and new customers.However, it is hard to see somethingnew in the conveyor industry. 

Most ofthe unit conveyor systems weredeveloped 15, 20 or even 50 years agoand are still sold today in a construction,which remembers on the patents of theBritish toy manufacturer Frank Hornby,who has already registered his patent ofa “Meccano” kit in 1901.Now, the two young founders of the start-up Avancon SA are ready to revolutionize the conveyor industry with thisnew and streamlined concept. It’s full of innovative and functionalideas and has been patented worldwide.

Originally, Dieter Specht had developed this systemfor Interroll. But it didn’t fit to their philosophy. So hefound two enthusiastic entrepreneurs, Denis Ratz,he has a bachelor of science in business informaticsand Dr. Daniele Gambetta, who has a PhD inelectric machines. They established inTicino/Switzerland a new start-up under the name Avancon SA (from Avant-garde and Conveyor).

The CEO, Denis Ratz showed the new conveyor system to some large and important manufacturers of conveyor- and logistics-systems and got a very positive response.

“Of course, we wanted to see the reactions to our completely new and very modern designed conveyor concept,” says Denis Ratz. “Most were positively impressed about the outstanding design. I could  answer all their questions about the functions and requirements of the  market. After these meetings with CEOs and technical managers of  big and well-known companies I was highly motivated. Now we are ready. Everything is finished and tested. We can deliver.  Several potential customers will visit our large test facility here in Ticino. We believe that the functions and the many advantages of this  innovative system will convince them.” 

Avancon SA invested heavily into development, in machines, in molds, patents and in the production. With a clever marketing concept enables an exclusive group of Conveyor Manufacturers and System Integrators worldwide to promote the system under their own label/brand and house color to the final market, the operators of logistics and distribution center.

Denis Ratz explains: “We want to offer something avant-garde to the manufacturers of conveyors and intralogistics systems. But we don’t want to interfere with the market of our customers and we will not offer to distribution- and logistics-systems directly to operating companies. Even though this modern system will catch the eye of every manager of this industry.”

The partner and head of technique, Dr. Daniele Gambetta, is an experienced specialist for electronic control and DC-motors. He has patents of completely new DC-motors, which will also be integrated in the future in the Avancon Conveyor System.

“Today – in the digital age of ‘industry-4’ – the electronic connectivity is of enormous importance. I was very fascinated by the ideas of Dieter Specht, so I have joined this young start-up,” says Dr. Daniele Gambetta. “I have never seen such a convincing new concept in the conveyor industry. Everything is completely different, new, safer and much better. We believe that about 80 % of all goods up to 50 kg weight, which have to be transported millions of times worldwide every day, can be handled with this new system.”

Meanwhile, the design has been awarded by the internationally well known “Red-Dot” price in Germany and also by the very coveted  throughout Asia, “Good-Design” award in Japan. 

The two partners have a lot of courage to break into such an  established market today. But who would not want to offer their  customers something very aesthetic, even revolutionizing, which differs  to all previous designs?  

Why aesthetic? Well, ask yourself: would you buy today a machine,  which is not modern covered? Now you can offer your customers  something extraordinary that combines innovation with emotions. 

Denis Ratz says: “We are very positive about the future. We have just moved into a newly built modern factory, which corresponds to our  DNA. Here we have a daily capacity production of up to 400 meters  conveyor tracks of our new ZPC- system. Anyone who builds conveyor  systems by himself can obtain all individual elements from us and so use the patents free of charge. Several customers want to exhibit the new system at one of their upcoming trade fairs.  

That’s fantastic!” 

‘ZPC’ system means “Zone Powered Conveyor” system, in which each zone is controlled and driven separately. The system is extremely flexible and  adaptable. It is capable of slow or fast transporting in  any desired line and, where necessary, can  accumulate without pressure. The system can also communicate with  higher IT or Bus system very easily and at significantly reduced  installation cost.  

Of course it transports goods in all directions, with all the functions an  engineer wants for logistics systems. 

Last but not least it seems to be much cheaper than it looks. 

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Conveyor Types

Automated sortation system installed specifically to deal with “small traffic”

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The UKs largest dedicated parcel carrier officially opened its new purpose built, 15,000 square metre, parcel distribution hub in Warrington back in 2014. Designed to support the continuation of growth of the company the new hub has a capacity of around 550,000 parcels a day – almost three times that of the previous site in Warrington.

The facility’s purpose was to help with the developing requirement for next day deliveries, playing a key role in plans for international expansion and to provide a platform for further innovation, as the company looks to introduce a host of new products to the market.

L.A.C Conveyor Systems Ltd is now entering its 4th year, working closely with the multinational delivery company, in the development and implementation of innovative, flexible technologies to suit the ever-evolving challenge of handling parcels from a wide range of shapes and sizes whilst achieving faster processing times.

L.A.C Conveyor Systems innovative

The latest challenge was to introduce a sortation solution specifically designed to accommodate small sized parcels. Prior to the new solution the sortation of “small traffic” was a combined sortation process, with larger parcels. This combined automated parcel sortation approach meant that smaller parcels were harder to control and ultimately ended up being manually sorted. This system required a lot of human intervention to gain full control, proving not the most efficient approach, as the accuracy of the sort could not be guaranteed. Separating smalls from larger parcels meant higher throughputs could be achieved utilising a more streamlined solution with a 100% accuracy of sort.

L.A.C Conveyor Systems innovative “Automation Toolbox” meant a combination of technologies could be combined to satisfy the required solution and could be delivered and implemented within a small footprint and with minimal disruption to current operations.

The solution utilised L.A.C designed induct/feed conveyors, handling bulk parcels on infeed for initial parcel separation, which were then separated further utilising a flighted belt conveyor, leading on to a horizontal conveyor with 5 moveable ploughs and 1 fixed. The parcels were then broken down further spread across 6 chutes, presenting parcels to an operator platform. Operator interaction at this stage of the process provided a means of orientating parcels and placing them onto a Equinox split tray sorter with barcode labels accessible for automated scanning and verification.

The Equinox split tray sorter is a tray-based “bomb-bay” sorter developed specifically to handle flat goods such as packets, books, garments, parcels, and accessories, making it the ideal choice for L.A.C to integrate as part of a turnkey solution. The system offers the capacity to sort 10,000 trays per hour exceeding the requirements, but offering scope for future growth. It has a characteristic oval-shaped conveyor on which the trays circulate. This “open oval” design allows operators and further automation to integrate with ease.

An overhead scanning system ensured parcel identification and location could be achieved at high speed. L.A.C’s modular software design structure offered a seamless link with the host IT system, completing the final piece of the puzzle.

This unique automation approach has ensured a fast and flexible response to future e-commerce demands and has enabled an increased ability to handle parcels of such a shape and size in such a controlled manner. L.A.C’s diverse inhouse skill set has offered a solution that is cost effective providing faster processing of incoming “small” parcels.

System Overview

Objectives

Modernising the supply chain network

System to handle small sized parcels only

Cost effective and efficient flow of goods to consumers

Selecting & implementing the best technology

Allow for more next-day delivery

Increased order accuracy

Overall reduction in costs

Integrate with latest supply chain technology

Key services & Technologies

Feed conveyor – shaft mounted motor, tapered hopper to allow product to fall onto flyted belt conveyor.

Modular belt conveyor with hopper

Discharge conveyor with high side for product control

5 off moving ploughs and 1 fixed. Underslung braked motor with pivot arm connected to plough

6 off discharge chutes

6 off operator stations

Each discharge station offering PTL button light module

Double tray wide oval sorter

Sorter gross capacity (10,000 trays per hour)

Tray type 7 DT Double Tray – (Bombay also known as split tray)

Sorter direction – Clockwise

Barcode label control linking carton to station

Item detection sensing

Omni Camera Scanner – Overhead system for barcode label capture

L.A.C IT hardware and Software integration

Wireless network connection

VPN Remote Access

Results

100% Accuracy of sort.

Increased supply chain efficiencies

Sortation direct into shipping cartons

Easy to use, simple efficient design and low maintenance decrease cost and increase uptime.

Design allows for the highest accuracy as well as a very small footprint without losing throughput.

Source:www.lacconveyors.co.uk

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