Compact design with a central conveyor segment / Processes practically all standard market container sizes and formats / Keg system can be flexibly expanded thanks to the modular design.
More flexibility, efficiency and speed: with its Innokeg AF-C Transversal the KHS Group provides a sophisticated setup that washes and racks up to 500 kegs an hour. Thanks to its single central conveying segment the system is particularly compact and perfectly accessible. If required, it can adjust to different formats fully automatically.
Compared to standard market systems, the Innokeg AF-C Transversal kegging machine scores on not one but several counts, declares Roger Daum, keg product manager at KHS. “The biggest and most obvious difference lies in its innovative conveying system. The conventional transversal conveyor setup used to date has separate belts for infeed and discharge upstream and downstream of the actual machine. The KHS design is consciously different and transports the kegs through the middle of the paired opposite processing stations on a single conveyor belt. On this they are pushed in and out of the line to the side.” The great advantage of this concept is that on the Innokeg AF-C Transversal there are no conveyors separating the operator from the machine. The stations are thus freely and much more easily accessible for maintenance and repair. The space-saving system also has a smaller footprint in the production shop. Moreover, with its inverse ratio of conveying to processing stations (compared to standard machinery) the KHS system is more powerful and can process up to 500 kegs per hour.
Modular and flexible
Another key difference of KHS’ keg engineering is its modular design that means lower procurement costs and that the Innokeg AF-C Transversal can grow to accommodate rising production capacities. “We combine two modules with two respective processing stations in a single block frame. Thanks to its compact design the block fits into a standard overseas container,” is how keg product manager Daum explains the principle of the system. Within this frame all kinds of cycle are feasible. “A machine can be configured with up to four blocks with two modules each. This is equivalent to 16 treatment heads that can function as a pre-, main or combined washer or filler respectively,” Daum emphasizes. This provides plenty of scope when configuring the overall line: twelve washing stations can be combined with eight racking stations, for instance, to balance the different cycle times. Individual modules in the block can initially be left empty and simply fitted with further processing stations at a later date should the necessity arise.
All-rounder for all formats
Another distinctive feature of the KHS Innokeg AF-C Transversal is that it can process practically all standard market container sizes and formats. Apart from the fact that no format parts have been used anywhere on the conveying system, thus rendering changeovers superfluous, if required request the entire line can be adjusted to different keg heights and diameters fully automatically. This optional system also recognizes whether the incoming kegs are returnable or one-way containers. The latter then travel straight to the filler through the deactivated washing machines without any conversion or treatment.
Right down the line
Before the kegs on the kegging line reach the Transversal modules, they are lifted from the pallet by the KHS Innopal RK palletizer with its six-axis articulated robot and placed on the conveyor. An on-demand turner with a fitting position detector and decapper ensures that the kegs are properly aligned and prepared for washing and racking. They are again separated and centered prior to exterior washing. In the washing machine a height control unit makes sure that slim kegs especially aren’t downed by the high water pressure of the cleaning nozzles.
The counterflow and pulsed cleaning processes yield optimum results at the pre- and main washing phases. Between these two steps the kegs are filled with caustic and left to soak, with the length of the conveyor determining the duration of the soaking time.
Filling is precise and regulation-compliant – thanks to the KHS Direct Flow Control filling system and gross/tare weighing that complies with the European Measuring Instruments Directive. Finally, ‘bad’ kegs or incorrectly filled containers that fall short of their nominal filling volume, for example, are emptied and removed from the line.
The kegs are then checked for leakage before they are sealed with a cap – if intact – and labeled by inkjet. Faulty kegs are discharged where necessary. At the end of the line the kegs are set down on pallets by a second KHS palletizing robot. This is equipped with double keg grippers whose heads can also be changed over fully automatically. “With the Innokeg AC-F Transversal, when it comes to efficiency and flexibility KHS scores on the washing and racking of kegs right down the line, so to speak,” concludes Daum.
At a glance: the Innokeg AC-F Transversal
- Less space needed thanks to the central conveyor segment
- Optimum access for maintenance and repair
- Modular design for flexible expansion
- Suitable for almost all market-standard returnable and non-returnable kegs
- Fully-automatic adjustment to different formats
- Up to 500 kegs per hour
The most common conveyor belt issues and how to prevent them
Like any type of machinery, conveyor belt systems will eventually experience issues from time to time. Regardless of how well-maintained conveyor belt parts are, it’s normal to face problems, especially given that conveyor belts are one of the most used pieces of equipment across many industries.
While some problems are bound to happen, there are ways to prevent common issues and extend the life of your conveyor belt parts. Below are some of the most common conveyor belt problems and ways to prevent them.
Material accidentally sliding, rolling, or spilling over is inevitable, especially for productions that move a lot of loose or heavy products. However, if your conveyor system is experiencing an increase in spillage incidents, it could be an issue with areas that are causing excess shaking or rattling.
To prevent material spillage, be sure to keep your conveyor system well-maintained. Clean the conveyor belt and parts regularly and consider installing impact beds.
Excessive material spillage is the most common cause of seized rollers, which can halt production altogether. To prevent this downtime, we recommend installing Luff’s patented High Moisture Seal & Anti-Lock Shield. This polymer disc sits inside the end cap and remains stationary as the roller rotates around it, allowing the roller to turn freely, even with material built up between the roller end and the conveyor idler.
In addition to Luff’s High Moisture Seal & Anti-Lock Shield, you can prevent seized rollers by carefully inspecting them on a regular basis. This should be part of your regular maintenance routine.
Material blockage can happen due to wear and tear on the conveyor belt, sharp edges, and weak points in the system. When blockages happen, they can cause the conveyor belt to simply stop moving.
To avoid this issue, again be sure to keep a well-maintained system. Inspect your conveyor belt for any holes, weak points, and sharp edges that could potentially cause a blockage and have them repaired as soon as possible. Another solution to prevent material blockage is to install guide rollers which help reduce the chance of severe belt damage from sharp edges.
Mistracked conveyor belt
Mistracking happens when the belt moves too far to one side, which can lead to material spillage, material blockage, and cause premature wear on other conveyor belt parts. A mistracked conveyor can throw off the entire system The best way to prevent a mistracked conveyor is to have inspections and adjustments done on a regular basis. If you notice small signs of misalignment such as uneven belt wear, address them immediately before they become bigger problems.
To sum it up, some of the most seemingly small issues can turn into bigger problems that can halt operations. These common issues can be prevented and solved with simple conveyor belt parts and accessories.
Plastic load carriers from the automotive specialist
A trouble-free internal material flow is one of the essential factors for efficient production of components for the automotive industry. Errors and faults in transport and storage systems result in time-consuming and costly interruptions. The Craemer Group, internationally established supplier to the automotive industry, is one of the leading manufacturers with large-scale production of automotive modules made of metal and large-volume load carriers made of plastic.
The automotive expertise of the Germany-based Craemer Group founded in 1912 has contributed to the development and production of injection-moulded load carriers made of sturdy plastic. Versatile plastic pallets and pallet boxes from Craemer reliably reduce downtime in the automotive and supplier industries.
Special plastic load carriers for customised applications
For more than 50 years Craemer has been developing and manufacturing durable pallets made of high-quality polyethylene (PE). Today, the extensive portfolio includes half pallets, Euro pallets and industrial pallets for a wide range of applications. One example from the company’s portfolio is the D1 plastic pallet with its 22-millimetre rim: It is specially designed for the automotive and supplier industry and ensures high load security when used with small load carriers (SLC) and clear packaging (blisters). Unlike wooden pallets, box elements can be transported precisely and safely, without strapping and fastening, thanks to the edge system.
Thanks to their 22-millimetre outer rims, the CS plastic pallets in Euro format and industrial sizes are also ideally suited for use with SLC. The ESD (electrostatic discharge) variants of the CS pallets are made of conductive material and protect sensitive components from uncontrolled electrostatic discharge. The CS pallet is optionally available with Palgrip® anti-slip runners.
The CR plastic pallets are ideal for heavy loads. They permit versatile solutions thanks to a load capacity of up to 1750 kilograms and an anti-slip coating on the deck which makes them ideal for high rack warehouses. On the other hand, Craemer H and TC pallets offer optimum hygiene conditions for sensitive processes. The H model is also available in a conductive version. The pallet portfolio for the automotive and supplier industry is complemented by the lightweight SL pallet in Euro format with an overall height of only 120 millimetres.
Safe transport and easier handling of commodities
For the automotive industry, particularly impact-resistant and splinter-proof pallet lids are an ideal complement to Craemer plastic pallets. They are available in Euro format and industrial sizes and are suitable for all common returnable containers (such as SLC). Thanks to their precise fit they close perfectly flush. Integrated strapping grooves and locks on the short sides of the lid optimise the load security of sensitive commodities. As conductive ESD variants, they also reliably protect electrostatically sensitive components from uncontrolled discharges.
Other products of the Craemer automotive range: CB pallet boxes. Thanks to the one-piece injection-moulded production and their sturdy construction, these large load carriers made from PE convince with their high resistance and long service life. They are available in Euro format and industrial sizes. In addition, they are UN-certified and thus approved for the transport and storage of hazardous goods. Precisely fitting lids are available as additional accessories. With its complete portfolio of load carriers and accessories, the Craemer Group supports safe transport and storage processes in the automotive industry.
Mondi partners with Heiber + Schröder to launch the new high-performance machine eComPack for automated packaging of its EnvelopeMailer for eCommerce
Heiber + Schröder’s mechanical engineering combined with Mondi’s packaging and paper expertise enables eCommerce companies to automate the erecting, filling and closing packaging process using the EnvelopeMailer solution he state-of-the-art eComPack doubles output per hour, responding to demand for the automation of paper-based packaging solutions in eCommerce operations
The state-of-the-art eComPack doubles output per hour, responding to demand for the automation of paper-based packaging solutions in eCommerce operations
The new machine perfectly complements Mondi’s universal and fully recyclable corrugated EnvelopeMailer for maximum performance
Mondi, a global leader in packaging and paper, has worked on an innovative collaboration with German machine producer Heiber + Schröder to create a high-speed automated packaging machine that meets the process, efficiency and safety requirements of eCommerce fulfilment operations. The new eComPack machine is designed for mid to large size eCommerce operations seeking efficiency and reliability. It can process up to 500 parcels per hour thanks to an automated erecting, filling and closing process.
The technological expertise of paper and board packaging automation expert Heiber + Schröder forms a perfect synergy with Mondi’s innovative packaging solutions. The resulting high-output eComPack can automatically process a wide scope of goods using one height-adaptable packaging design that is available in different sizes. The equipment stands out for its compact floor space requirement and simplicity in operation and maintenance.
In the rapidly growing world of eCommerce, the combination of an excellent paper-based product and an efficient and economic automated packaging machine is a key differentiator for our customers. The successful introduction of Mondi’s EnvelopeMailer solution increased manual packaging output by 8% compared to standard C-folder packaging. With eComPack, we are now enabling our customers to double their output and optimise packing operations in fulfilment centres handling high volumes,
Tarik Aniba, Sales & Marketing Director, Mondi Corrugated Solutions
The eCommerce market has grown significantly in recent years, accounting for approximately 20% of global retail sales in 2021¹. This means a wider variety of goods is being distributed, which increases packing complexity and requires versatile packaging solutions of different sizes and shapes. At the same time, with the rising cost of labour, the desire for packing machines in eCommerce is more prominent than ever before. To help customers tackle these challenges, eComPack provides a solution dedicated to the automated packaging of Mondi’s corrugated eCommerce solution EnvelopeMailer.
Made to safely fit single or multiple items and rectangular as well as irregular shapes up to 7 cm in height, the EnvelopeMailer’s flexibility in the fulfilment process, efficiency in handling, and economical use of material and space have made it an all-around new standard in the market since its launch in 2020.
André Garmer, Managing Director Heiber + Schröder, adds: “Together with Mondi we developed the machine in a very dynamic co-creation process. The result is a robust, user-friendly machine with top-class usability. Through clever and responsible creation, we were able to synchronise packaging design and machine functionality into a solution that offers tremendous potential if combined with the right packaging solution.”
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