Challenge:
Core purpose of our customer Knauf is to reduce manual labor in production area for reasons of safety, ergonomics and cost efficiency.
Knauf operates three packaging lines supplied with empty pallets from a magazine holding up to 15 pallets from outdoor storage.
Customer’s technical requirement comprises each pallet to be covered with a PE sheet before stacking bagged products in order to prevent contamination from moisture or dirt. Manual application was time-consuming and prone to errors.
During transport of the empty pallet from the pallet magazine to the position where products are automatically stacked, the sheet may fold or shift, causing disturbances to photo sensors and disrupting the logistics process during empty or full pallet transport. The location where the pallet sheet dispenser needs to be installed has limited space available.
Solution:
Induquip International was commissioned to supply a pallet sheet dispenser with two integrated stapling machines.
The process works as follows:
- The empty pallet moves under the sheet dispenser while the PE sheet is rolled out synchronously just above the pallet.
- After 100 mm the pallet stops and a staple is applied to each corner to secure the PE sheet to the pallet.
- The pallet then continues moving.
- At the end of the pallet, it stops again, the PE sheet is cut from the roll, and the corners are stapled once more for extra security.
ROI:
With this solution, the customer was able to recover the investment within 1.2 years. Line disruptions were reduced by more than 14%, significantly increasing the line’s capacity in stacked bags per hour.
Integration Options for PE Sheet Dispenser:
The PE sheet dispenser can be installed above any pallet transport rollers or chain conveyors, at the correct height and width of the line, with two optional stapling units. Suitable for OEM solutions and integration.
