IDM ¦ Packaging
In the used palletisers the
changeover of pallet type
takes place via stored product
settings. This is also the
case with the layer pattern.
being inserted into an open plastic tray
that was additionally wrapped in shrink
film prior to palletising. “Now we pack our
cups in solid cardboard sleeves and corrugated
cardboard cases,” Strike adds.
In addition to this challenge, a suitable
plant layout had to be determined in order
to be able to spatially incorporate the
planned palletising centre with integrated
packaging unit in the respective hall intended
for this purpose. Furthermore, all
existing options from cup filler to product
routing were to be maintained. This
is where flexibility in the packaging unit
design, with its tray erector and sleeving
machine, was hugely important. Because
this would ensure that the cups could leave the filling line in the
existing format and still be processed in a seamless manner by the
new packaging and palletising line“, Strike explains.
Successful award of contract after
an extensive tendering process
The first stage in choosing a machine was an elaborate tender process.
Strike recalls: “It was here that the tray erector and sleeving
machine stood out from the rest as well-established and proven
flexible machines.“ And there was a further additional advantage
over the competitors: the existing equipment could be adapted to
the new conditions without any difficulty whatsoever. Choosing
one of the other bidders would have necessitated an investment
by Premier Foods in replacements. “So the final decision was relatively
easy for us”, Graeme Strike continues.
The contract included the layout, two new palletisers, the conversion
of an existing palletiser, a multi-former tray erector and a
SetLine sleeving machine, also all required conveyors as well as the
mechanical-side and control-side connection to the specified interfaces.
Two spiral conveyors were purchased and integrated by the
general contractor. Equipment from third parties was also taken
over, such as X-ray-checkweighers, Inkjet printers, pallet wrappers
as well as pallet and case labellers.
14 · September/October 2022 ¦ international-dairy.com
During the plant planning, particular attention was paid to ensuring
the most energy-efficient operation possible – one of the
goals being to minimise the use of expensive pneumatics. Consequently,
the most up-to-date servo drives and three-phase drives
are used, and vacuum pumps replace conventional Venturi vacuum
generators. The entire project was managed on a turnkey basis,
including the dismantling and training of operating staff.
Specified output reached in
record-breaking time
Assembly work in Lifton started at the end of 2021. The new
packaging and palletising centre reached the specified output in
record-breaking time. Acceptance was successfully completed in
February 2022, just a few weeks after the commissioning. “This
was also made possible thanks to the excellent operator training”,
Strike emphasises. Another useful tool in this respect was, of
course, the “digital twin”. This system is used in the run-up to an
investment to determine via computer simulation how to best implement
the task set by the customer in a technically and economically
expedient manner. In the Premier Foods project this focused
on the design of the pallet transport system. However, the “digital
twin” can do a lot more than just computer simulation. The tool
runs the exact PLC that is to be used by the customer, and this in
turn controls the simulation. The knowledge gained in these tests,
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