Complete lines and handling systems

Transcription

1 MOVING IDEAS Complete lines and handling systems The development of a packaging line for fast moving consumer products, technologies for handling containers, packs and pallets, as well as integrated traceability and storage systems Text by Manuel Bolzoni, Gabriele Folli, Glauco Cima, Giuseppe Buttazzi. Paolo Ferri OCME Competence Library

2 Machine series OCME designs, manufactures and installs filling, packaging, palletising and handling machines for all the major mass consumer product manufacturing sectors. OCME machines are the result of decades of experience and are designed to become the backbone of our Customers production division. High and low level depalletisers Roll-fed labeller Level filler for beverages In-line and rotary volumetric fillers In-line and rotary weight fillers Shrink-wrap and tray-packers Wraparound packers Combined wraparound and shrink-wrap packers High and low level palletisers with 90 infeed In-line high and low level palletisers Robot palletisers Automated guided vehicles Computerised control system DORADO ANTARES SAGITTA HYDRA LYNX LIBRA VEGA ALTAIR GEMINI PERSEUS ORION PEGASUS AURIGA ALBATROS

3 Complete lines and handling systems The development of a packaging line for fast moving consumer products, technologies for handling containers, packs and pallets, as well as integrated traceability and storage systems Contents Introduction Packaging lines for the fast moving consumer industry Development of lines The ideal factory Control, interface and alarm systems PLANT supervisor (optional) Handling systems inside the line Conveyors for empty and full loose containers Conveyors for empty containers in bulk Conveyors for full containers in bulk Conveyors for secondary containers (bundles, cases, multipacks etc.) Conveyor logistic components Roller conveyors Pallet conveyors Auriga automated guided vehicle and rail trolleys Materials and forms of transport Research and Development Advantages for the marketing division - Advantages for the administration division Environmental respect: an opportunity to distinguish yourself at ethical level OCME Competence Library

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5 5 Introduction It s not because things are difficult that we dare not venture. It s because we dare not venture that they are difficult. Seneca (from Letters to Lucilius) D esigning and building efficiency is a great challenge. In a packaging line, this means making use of a great number of heterogeneous resources, each of which contributes to the final result in its own way. First of all, a lot of experience is needed. Managing flows coming in and going out from best performing and highly efficient machines, which sometimes interface with pre-existing devices or third parties, requires that designers and analysts can draw on a broad experience of installations to be able to anticipate and avert critical situations in the flow of products, as well as support maximum productive fl exibility. The ability to innovate is also of the essence. Studying new solutions, testing and adapting innovative materials and cutting edge technologies are up to those entrusted with the task of developing a packaging line upon which the competitive advantage of a company is based. A modern fast moving consumer industry can actually be compared with a living organism given the complexity of the production and packaging systems it uses and its own competitive role on the market. Its success will fi rst of all depend on the effi ciency of its internal structure. Process machines, fi llers, packaging machines and palletizers are organs of the corporate organism ; however, without optimal coordination and planning of product and data fl ow they would be useless devices. Therefore, the infrastructure of conveyors, handling and data exchange can, fi guratively speaking, be assimilated in the circulatory apparatus and the nervous system based on the effi ciency of which the level of performance and the overall level of the company can be determined. Thus, will this organism be a pray or a predator? Will it be an athlete or a heart patient? Will it know how to adapt, develop and rise to future challenges or will it be affected by shortsighted choices, unexpected events and obstacles?

6 6 OCME Complete lines and handling systems Packaging lines for the fast moving consumer industry The implementation of a complete packaging line for fast moving consumer industries involves a great number of different jobs and requires preparation, high level services and considerable specialization. O CME has established itself as a leader on the world market by developing some of the milestones in the history of packaging, logistics and palletizing. Speaking of OCME machinery and lines means speaking of elite systems, high-efficiency and top productivity systems studied to make up the backbone of the productive sector of our customers. OCME operates in numerous fast moving consumer product sectors; let us highlight the following. Soft drinks For the soft drinks sector OCME is able to provide the complete bottling, packaging and palletizing line by integrating machinery of its own production with equipment of third providers. In this framework OCME has worked with producers of very different products such as: mineral water, carbonated drinks, spirits, wine and beer. Food sector For the food sector OCME proposes fillers for creams or thick liquids, secondary packaging machines and end-of-line plants. OCME has manufactured complete plants for producer companies both of food products and animal feed and has dealt with numerous specific cases. Home and personal care products For the sector of home and personal care products OCME is able to provide the complete filling, packaging and palletizing line by integrating machinery of its own production with equipment of third providers. Petrochemical For the petrochemical sector (lubricant oils, chemical products etc.) OCME can provide the complete filling, packaging and palletizing line by integrating machinery of its own production with equipment of third providers. OCME has been working in the petrochemical sector since the beginning of the seventies and has offered a great number of installations for all the leading companies worldwide. 1 Tissue For the tissue sector OCME proposes integrated end-of-line automation systems, which take over products at the outfeed of packaging machines for palletizing and managing pallets from the end-of-line to the warehouse of finished products. Figure 1 OCME provides plants and solutions for a wide range of products and containers.

7 Development of lines Ordering Customer-oriented skills and ability to interpret the customers strategic and commercial demands are among the main characteristics of the OCME pre-sales personnel. They are specialized advisors in different sectors that can draw upon the rich technical heritage of the company using advanced systems for the analysis of product flows and simulation of real production conditions in plants. Design The design of the line being performed with the most advanced design and planning instruments is a phase requiring excellent skill and outstanding ability to interpret the technical and commercial evolution of companies. The Research and Development department (which finds its ultimate expression in the Integrapack experimental laboratory, see below) supporting designers and having an entirely innovative approach, continually experiments with advanced solutions to transform them into powerful industrial tools. Implementation and training The delivery and start-up of a line is coordinated by means of advanced information systems, which allow for maximum efficiency of the personnel and guarantee the fulfilment of contractual commitments, both in terms of quality and as regards the project implementation timing. Furthermore, OCME can offer a whole series of training courses that enable the personnel of our customers to perform outstandingly even in terms of safety. OCME training courses range from courses for machine operators to those intended for maintenance staff. During these sessions your employees will learn all the necessary notions on how to use our machines in safety. Irrespective of the kind of training you choose, OCME will always provide you with a balanced mixture of theory and practice. Support and service For all after-sales services OCME provides each customer with a separate key account, which assists customers in making the right technical or financial choice every time. This is to underline that our main concern is to try to offer our customers the best possible service every day. Maintenance and spare parts OCME spare parts are the best in terms of price, availability and quality. All spare parts exiting OCME warehouses have actually passed the most rigorous quality checks; thanks to our logistics network spare parts reach their destination within the shortest time possible. Project Management The OCME Project Management service develops the assignment over the 5 phases of the project life cycle (start-up, planning, monitoring and control, implementation and completion, carrying out its mission both externally and internally within the Company. Its role is to manage and improve communication among all parties, both customer and sub-supplier, whilst reducing the risks which may arise due to complications during project development and also improving the quality of all processes. Equally important is the Project Manager s work within the Company, where he aims to communicate all relevant information to the Project team clearly and promptly, reduce errors by clear, improved process design and ensure attention to detail regarding the allotted timing programme and budget.

8 8 OCME Complete lines and handling systems The ideal factory: infrastructure he sensors network, the T control surfaces and related interconnections of a packaging line are the nervous system of the human body. They let you know what is happening and, consequently, how to intervene. The quality of network infrastructure is measured against the ability of the company to control all parameters, promptly manage either changes in production and alarms and management of machine stops by enabling tele-assistance services. OCME has been one of the first companies to develop an extended lines control system; today it actually has an over twenty-year old experience in the management of problems related to the dissemination of ingoing and outgoing production data from corporate information systems. 2 Figure 2 Example of a complete line with conveyors with full and empty containers in bulk and conveyors for packs and pallets.

9 3 Figure 3 Management of all components of the line. Network infrastructure (Ethernet OCME) The OCME solution for the production line automation and is made up of a well-tested and highly reliable system for information sharing in real time between all entities present in the factory. Ethernet OCME network is made by highly qualified specialized technicians able to guarantee optimal operation and maximum availability of infrastructure. The network, which is partly wired and partly wireless, enables the different components of the plant to communicate. Figure 4 Centralized adjustment of the palletizer infeed guides. 4

10 10 OCME Complete lines and handling systems The ideal factory: control, interface and alarm systems Optimal interaction and integration between production line, corporate information system, logistics system and, finally, operators is a necessary prerequisite for aiming at maximum efficiency. C ommunication of warnings, alarms, operative status and the entire flow of incoming and outgoing information from the production line must always be accessible to the company. To this end there are a lot of interfaces between systems (e.g. between operative systems of lines and corporate information systems) and between systems and operators. Said interfaces and points of contact are crucial to achieve maximum efficiency and correctly manage any event, including occurrences linked to the health and safety of people at work. Let us list some of the devices used in the OCME lines, which allow for informing operators in real time and setting the operative parameters of the active components of the line. Calculation of accumulations of the line Depalletizer +20% Indicative values for the sizing of the filling line Palletizer +30% Bottle inspector +30% Packaging machine +20% Labeller +10% Filler 100 (Master machine)

11 Control panel For all conveyors (cartons/bulk/pallets etc.) the concept of modularity and mechatronic integration has been adopted. All conveyors are actually managed by inverters integrated in the motor by means of which speed and start/stop ramps can be set according to the material transported. For each conveyor an interface is also foreseen for inverter control and the connection of field sensors. Cabling occurs by means of a power bus for motors and a field bus for signals. All conveyors are controlled by an electrical panel able to manage from 25 (basic version) to 50 motors. Pushbutton panels They allow for communication of simple information, such as the running and reset of an area and enabling manual mode. The pushbutton panel can be equipped with a 10 touch screen operator panel upon request. Operator panels Each control panel is equipped with a 12 colour touch screen operator panel by means of which the operative status of conveyors can be analyzed easily and intuitively. The standard operator panel is made up of a main page displaying the table of contents with the operative statuses highlighted and giving access to the other menus. From the operator panel it is possible to: Enable manual mode Set the main operating data Set the operating data of the single motor Display the state of interfacing signals with machines Display/modify data tracking Display alarms 5 6 Figure 5 Simulation software for the robot palletizing plant with manipulators. Figure 6 Simulation software of a plant with automated guided vehicles.

12 12 OCME Complete lines and handling systems The ideal factory: control, interface and alarm systems Display (optional) Displays of different sizes and types can be arranged in different points of the plant to allow for easy reading of the main alarms/signals of conveyors. Tele-assistance (optional) All machines connected with the OCME ethernet network installed at the customer s facilities can be monitored from our offices via internet (or even suitable telephone lines). Albatros (optional) It is software completely developed by OCME with WINDOWS XP Embedded as operative system. A 15 touch screen PC is used without any devices with moving mechanical parts and is thus highly reliable. There are no fans and it uses a compact flash memory as mass memory. It is connected to the PLC of conveyors via ethernet network. Compared to the Operator Panel it offers additional functions concerning self-diagnosis, production data, planned maintenance, tele-assistance and communication management.

13 13 PLANT supervisor (optional) An updated version of ALBATROS that consents better control of the line and improved integration of the transport system with the machines making up the line. All ALBATROS features are maintained and are extended to all the components of the line. It is an intelligent self-diagnosis and monitoring system for machine and system functions and consents filing and processing large amounts of data, through the use of databases. Plant supervision is realized through the use of SCADA packages, so the software licence fee must be paid. The standard development software used is INTOUCH produced by the Wonderware corporation with WINDOWS XP / WINDOWS 7 operating system. A DESKTOP PC is used, housed inside a special cabinet or in a special Control Room. In its maximum extension, the system is composed of an OCME interface server with the customer s management system and an operator workstation that will serve as both MES and SCADA. The software has been developed to adapt to plant requirements: Possibility of connecting to the machines of the entire plant and therefore remote start-up /alarm display / production data for each machine. Possibility of connecting to all plant devices (labelers/code readers, etc.). SAP Customer Ethernet line Possibility of connecting to customer information technology systems to receive and manage production orders and product master data records and provide for production data and traceability. Whole system diagnostics Production statistics / Alarms for the entire plant OEE calculation for individual machines and for the entire line Sole master data record for the entire plant Production batch management Product traceability management Driver for all the PLCs Computerisation of all forms currently fi lled out by the various operators in paper format, and generation of documents for fi ling purposes. Server OCME OP / plant data collection section Linea Pc Pc LGV Warehouse PC OCME Ethernet Line - OP / line machine data collection start OCME Automated warehouse Depalletiser Filling machine Labeller Wrap-around packer Palletiser Labeller Taping machine LGV

14 14 OCME Complete lines and handling systems The ideal plant: handling systems within the line Conveyors for empty and full loose containers Each sector, indeed each producer or company, has specific needs in terms of handling primary containers such as bottles, packages, boxes, shaped bottles or any other type of object, but all sectors have shared needs in terms of efficiency and maintaining the value of the investment over time. H ence, guaranteeing excellent performance is only one of the characteristics of a good, integrated handling system; other requirements include high manufacturing quality and excellent materials, which allow for a long service life, in addition to specific measures against frequent maintenance requirements, the accumulation of dirt and various pollutants. Furthermore, in the final analysis, a conveyor system for primary containers must meet specific product requirements and must be upgradable over time, based on the company s strategic long-term choices. In terms of primary container handling, the need to transport empty or full containers must be distinguished the one from the other, a need that is particulary felt in the beverages sector where, in specific cases, very high-speed air converyors are used to transfer PET bottles. Whether the containers are empty or full, the handling devices must be designed based on a close analysis of the line s production flows, with an accurate and reliable simulation of all situations, including critical ones, that may occur. For this reason, OCME uses special software for the correct sizing and configuration of the entire handling line. Type of conveyor Suitable for Air conveyors Separator from 1 to multiple rows Slat conveyor Pressureless combiner Slat conveyor Pressureless combiner Pressureless accumulator Track separator Rubber slat elevator/lowerator Cable conveyors Table key PET empty Empty tins Empty glass PET bottom Flat PET bottom Petaloid Glass Tins Jerrycan Cases Shaped bottles

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16 16 7 OCME Complete lines and handling systems Conveyors for empty loose containers Air conveyors Typically used for PET bottles, air conveyors are used to transfer containers exiting the blower up to the filler. The purpose of the conveyor in this stage is to bring the containers to destination with minimum energy consumption. This is done by taking advantage of the extremely light weight of the containers, using a controlled ventilation and suction system which, thanks to the flow of air that it generates, moves the bottles forwards at an extremely high speed. Air conveyors are designed in a modular way, for easy positioning and and re-positioning in case of changes in the plant layout. The hulls may be inspected for cleanliness and sanification and are made of AISI 304 stainless steel, to guarantee both maximum hygiene and maximum durability. The motors used for the system fans are equipped with safety knife switches that may be managed by means of both the inverter or by direct operation. Based on line requirements, there are various types of air filtering systems, steel or varnished. To ensure maximum efficiency and minimum energy waste, the pack guides are made of work hardened stainless steel or plastic with a low friction coefficient. A series of specific technical measures guarantee the elevated efficacy and efficiency of the air handling system, among which: Manual body guide adjustment system for mono-format lines, rapid manual system by means of speed set, automated format changeover using pneumatic pistons Use of flow control valves to control bottle speed Electronic recipe management systems to parameterise the plants Limited maintenance thanks to the use of top-quality components. Conveyors for glass and tins While air conveyors represent the optimum solution for PET bottles, for loose glass and tin containers we also adopt other types of conveyors, based on layout and plant environment requirements. Cable conveyors, slat conveyors, modular mats, magnetic or rubber slat elevators are but some of the solutions offered. 8 Figure 7 Detail of the air conveyors with automatic adjustment guides. Figure 8 Air conveyors for PET bottles.

17 Conveyors for full, loose containers Slat conveyors and modular mats Slat and mat conveyors are traditional conveyors for loose containers incoming to packaging machines. The purpose of this part of the handling system is to ensure that the containers or products reach their destination, which is cartoning machine, shrink-wrap packer infeed etc., with the least damage possible, with limited energy waste, and as quickly as possible. The growing trend of using primary container designs that are increasingly diffi cult to handle and increasingly instable further complicates the task of these conveyors. The large number of products, packaging shapes and materials calls for the use of specific technologies for each application. OCME conveyors are designed based on a modular logic that allows for units that may be easily positioned in any layout, simultaneously optimising the need for materials and spare parts and providing significant savings that derive from standardisation. Simplified cleaning A common feature shared by many different sectors is the need for a simplifi ed process to manage maintenance, cleaning and, generally, any other routine operation normally performed on the equipment. This is why the conveyors carrying the products to the wrappers are made in an easy-to-sanitize AISI 304 stainless steel. OCME conveyors are equipped with interesting features that help prevent dirt from accumulating and which are specifi cally designed to limit the extent of fl at surfaces, where dust and water can collect. In order to do so, the sides feature round spacers, profi led plates, rounded corners and sloping bearing supports. Drip collectors are positioned under the conveyors with a special V-shaped section that prevents dirt from collecting and consequently damaging the machine. The electrical cable tray onboard the chain is of the Cablofi ll type, and is positioned in an upright position to minimize accumulating dirt. Figure 9 Example of line with conveyors for full containers. 9

18 18 OCME Complete lines and handling systems Conveyors for full loose containers Continue Mechanical simplification Every additional mechanical component implies potentially higher maintenance costs and risks of failure. OCME has carefully planned the mechanics of its conveyors by applying a direct motor drive on the shaft to prevent the use of transmission chains, reducing the dispersion of energy. Configurations Conveyor configurations vary significantly depending on the needs of a given production line and of the products to be processed: Traditional conveyors with side transfers typically used in the bottling industry. With head passages to avoid lateral shifts. Modular belts are used with a pitch of ½ inch and a dead plates between two conveyors. This solution is used to solve the problems related to the sizes of the typical pallets or when the product is arranged into several rows. With sloping side transfers to create continuity with the work plane. In this case, the system does not include dead plates and lateral deviations of the product and guides. This solution is used when the product is arranged into several rows and/or when handling smaller articles especially if they have a particular shape and therefore more unstable. Quality of components OCME uses exclusively high quality components in order to guarantee the overall performance of the lines over time. This solution also has the objective to allow customers to have easy access to general spare parts, which can be easily found and match industrial standards. Figure 10 Slat conveyors for mineral water bottles. Figure 11 Slat conveyors for PET bottles for cooking oil

19 Lateral guides The lateral guides are designed to provide a side barrier for the products as they advance along the line, preventing them from falling off the conveyor. When the products contact the guides they may be exposed to friction damage or even tilt. Therefore the choice of the best shapes and materials to be used for the guides is fundamental to handle different products properly. An important feature is the ability to rapidly adjust the guides during the format changing operation. OCME has developed a series of solutions capable of meeting the many different needs of companies operating in different sectors. Lateral guides can therefore be designed in different ways: Steel rods, typically used with pet bottles Roller guides, when the product may risk to get stuck into the guides themselves In commercial polystone to guarantee smooth riding In specifically profiled polystone to protect, for example, the containers labels In aisi 304 stainless steel sheaths to protect bottom labels to be used in multi-channels solutions with independent rows. Based on specific needs, guides can be either fixed or adjustable. Adjustment can be made in several ways: manually with 2 reference rings for 2 positions manually with the aid of reference adjustment templates with centralized handwheel for fixed axle base on conveyors for independent rows with centralized handwheel for variable axle base on conveyors for independent rows with octagon plates with reference templates on each face on conveyors for independent rows. adjusted automatically with gear motor. Figures Plate distribution device for cases containing glass bottles. Figure 14 Extraction conveyor for PET bottles. 14

20 20 OCME Complete lines and handling systems Conveyors for full loose containers Continue Type of chains Materials, type and special requirements determine the choice of the chain that best meets the needs of a given product. OCME uses a wide range of solutions depending on the system s needs. Chains may be: In polyacetal with a thickness of 4 mm for standard conveyors In polyacetal with a thickness of 8.7 Mm for longer lifespan and better flatness In delrin kevlar with a thickness of 4 mm when less friction is required (unstable product) In delrin kevlar with a thickness of 8.7 Mm when less friction (unstable product) and longer lifespan are required In stainless steel when very harsh glass bottles are carried Modular belts with a thickness of 8.7 Mm for longer lifespan and better flatness. Lubrication Slat conveyors for loose products are lubricated in all except very rare cases. This will reduce friction between the product and the chain in order to avoid products from falling off the conveyor or getting stuck. Proper lubrication also reduces the noise produced by the line and increases the lifespan of the chains. Lubrication includes: A wet lubrication system, which consists of a pump that mixes the amine-based lubricant with water and, via the nozzles at the end of the conveyors, sprays it over the chains; the drip collectors under the conveyor body will collect any excess liquid. A dry lubrication system, which also consists of a pump that dispenses the silicon-based lubricant via special nozzles at scheduled intervals. Though dry lubrication is much more efficient, wet lubrication will keep the conveyor constantly clean and sanitized, which instead must be performed manually from time to time when using the dry lubrication technique. Slat conveyors for loose products can be equipped with a cleaning system made up of nozzles positioned inside the conveyors body and connected by means of pipes to a pump that will perform a cleaning cycle launched from the control panel. Figure 15 The passages between conveyors sections with dead plates for unstable containers. Figure 16 Slat conveyors for lubricant oil tanks

21 Figure 17 Slat conveyors with bridge breaker guides for bottles. Figure 18 Chain distribution device for shampoo bottles. Figure 19 Non-stop passage with slat conveyors sided obliquely. This is particularly indicated for unstable containers. Channels can be automatically adjusted using a handwheel. Figure 20 Lubrication nozzles for slat conveyors.

22 22 OCME Complete lines and handling systems Conveyors for full loose containers Continue Conveyor components for loose containers The products carried along the line need to be properly managed in order to deal with specific logistic issues. For example, it could be necessary to deal with different heights, or speed decreases and increases. Other examples are illustrated below: Decrease in flow rate without pressure, which will distribute the product from a fast single-line conveyor to a multi-line conveyor thanks to different speed variations and will accumulate the product that will be re-used as soon as the speed increases. Accumulation conveyor without pressure, particular useful in case of machine downtime downstream, and that will collect the product and re-use it when the machine resumes operation; thanks to different speed adjustments and electrical controls, products are not pressed against each other, and bottles and labels are not damaged. Extraction conveyor without pressure to move the product from bulk conveyor to single-line conveyor; this is necessary to introduce labellers or other equipment. Thanks to speed differences between one chain and the next, the product is easily aligned without pressure and will not damage or drop the bottles. Pad elevators are special handling systems used in the filling and packaging lines to change the height of the conveyor carrying the products in a very restricted space and at very high speed. The distinguishing feature of this system is that is has a continuous movement (unlike other typical elevators with an alternate movement). Special lateral pads (grippers), moved by means of articulated chains, will take hold of the products securing them at both sides and laying them at a different level. This technology guarantees great productivity together with an excellent and easy-to-use management (possible unmanned environment). Figures Distribution device with 2 to 4 lines for loose containers driven by brushless motors to obtain high speeds without compromising the containers stability

23 Belt distribution device. This machine is used to break down the product flow from one row into many different rows. It consists of a moving arm, around which 2 belts rotate to separate the products. The belt can be moved by brushless motors for a more accurate precision, and are used for small-scale productions, in case of large-scale productions the following are used: Multi-line distributer. These are special machines designed to distribute individual, unstable products or packages to several rows at an elevated intervals. The main fields of application include the food & beverage industry, pharmaceuticals and chemicals (especially the sector of detergents, personal care and petrochemicals). The main applications include: 1. Arrangement of the individual product onto the number of lines necessary to create the secondary package (heat shrink or wraparound carton) 2. Preparation of the pattern for top loader wrappers 3. Preparation of the palletising pattern for loose products 4. Selection and balancing of outfeed ways based on many different criteria (colour, label, etc) in order to prepare secondary packages containing different products with pre-set quantities. 26 The control of the main movements occurs through servomotors at a consequently high format change rate, making this type of machine particularly suited for multi-product lines. Figure 23 Plate distribution device for lubricant oil tanks. Figure 25 Belt distribution device for case with 1 to 4 lines. Figure 24 Infeed conveyor for glass bottles. Figure 26 Belt distribution device for shampoo bottles with 1 to 4 lines.

24 24 OCME Complete lines and handling systems The ideal plant: handling systems within the line Conveyors for secondary containers (bundles, cases, multipack, etc.) In order meet both distribution and marketing needs, every component of the line must be ready to process ever more advanced products and increasingly complicated handling issues O nce products have been placed in their secondary packages, namely cartons, multipacks, bundles, cases or other packages, they must travel along the route that separates them from the end-of-line division where they will be entered into appropriate palletizers. The needs of this section of the packaging line are similar to the ones concerning the carrying of loose un-packaged products, except for the differences in volume and weight of the products to handle. Therefore the need to clean and sanitize efficiently the conveyors remains and prevents the formation of dirt that will keep them safe at the hygienic level and also prevent potential long-term damages that could affect mechanical and electronic components. Adequately designed and manufactured conveyors carrying products to the palletizers must also take into account daily operation, and maintenance should be carefully handled throughout the entire life cycle of the equipment. Table key Cases Multipack Trays Plastic crates Tissue bundles Pails Cartons PET bundles Drums

25 Type of conveyor Suited for Chain-driven roller conveyor Roller modular belt accumulation conveyor Twin chain with padded modular belt Rotation with two modular belts with differential speed rates Transfer conveyor with modular belt Slat conveyor for multipack Plate distribution device Bypass chain-driven roller conveyor Flat chain-driven roller conveyor API chain-driven roller conveyor Twin side belt Twin side belt with pen Motorized roller conveyor bend in plastic Motorized roller conveyor bend in steel with close pitch Idle roller curve 90 diverter with idle rollers 90 diverter with motorized chains Plate distribution diverter Pads elevator/ lowerator Alternate cycle elevator/lowerator Step-by-step elevator/lowerator Continuous level elevator/lowerator Chain elevator conveyor In-line 90 tilter Lateral 90 tilter 90 rotation device Motor roller conveyor for drums Selection device for balance drums 90 diverter with motor chains for drums Cartesian axis manipulator Manipulators with anthropomorphic robots

26 26 OCME Complete lines and handling systems Conveyors for secondary containers Continue Figure 27 Motorized automatic guides for passages from 1 to 2 rows on a conveyor for bundles/cartons Figure 28 Conveyors for bundles and cartons from wrappers to palletizers.

27 Slat conveyors and modular belts The different types of conveyors designed for secondary packages must be selected according to the nature of the product to be processed, including its fragility, abrasion risk and lastly, the stability of the package itself. The structures of the conveyors are made in AISI304 steel, ensuring a longer lifespan and making the conveyor easy to clean, which is fundamental not only for food & drink applications, but also for many other sectors. OCME conveyors for secondary containers are the result of many years of research and tests, and are designed and manufactured to minimise the extent of fl at surfaces where dust and water may collect. This feature is also ensured by other elements such as the use of round spacers on both sides, shaped plates, rounded corners and many other elements. The electrical cable tray is onboard the conveyors and is of the Cablofi ll type, and it is installed vertically with comb-collected cables to prevent the accumulation of dirt Top quality motors and components One of the primary goals of any modern wrapping system is the careful planning and optimisation of the driving forces. Conveyors play an important role since they are equipped with motors and transmission components. In order to limit the use of the mechanical parts, OCME uses direct motorizations on the shafts. This eliminates the need for transmission chains and leads to several advantages: less mechanical components which are prone to wear and maintenance less driving force due to the reduction of energy dispersion less noise in the production area The sliding of chains and belts are in thick, high-density polystone for long operating life and reduced maintenance. OCME uses high-quality chains and belts to guarantee elevated performance and to allow customers easy access to spare parts. Modular logic The structures of OCME conveyors comply with commonly accepted industrial standards, whilst allowing a wide range of dedicated components to meet the needs of different products. Therefore it uses a modular logic that includes standard elements that can be easily used be designers based on layout needs. Thanks to this approach, maintenance is easier and spare parts can be quickly replaced because components are commonly available on the market and are easily interchangeable. All conveyors transfer products from one area to the other in the smoothest way possible, and where necessary, it can accept idle rollers. This enables greater stability to products during handling and especially as they pass from one area to the next whilst protecting the internal product from collisions, jolts and vibrations that can break or damage the product. 31 Figure 29 Detail of the transfer from belt section to roller section. Figure 30 Slat conveyors with manipulators. Figure 31 Automatic motorized length adjustments of the channels in a package conveyor.

28 28 OCME Complete lines and handling systems Conveyors for secondary containers Continue Conveyor logistic components Accumulation conveyors Conveyors with modular roller belts required to collect bundles. Braking conveyors Conveyors with a padded modular belt for low pressure accumulation. Twin belt conveyor Conveyor with two belts running at different speeds, including a modular padded belt to separate bundles from each other before they enter a curve or are counted or enter another machine (e.g. labeller or weight control); they can have one motor and a pinion-and-rack transmission to generate a fixed speed rate of the 2 belts, which is managed by an inverter. Rotations Conveyor with differentiated speed with 2 or 3 modular belt chains that rotate the bundles at different belt speed rates. This will allow a smooth rotation, without damaging the product. Transfer Transfer conveyors are performed on modular polyacetal belts in case of horizontal transfers or modular padded belts in case of elevating conveyors. 32

29 Distribution devices with manipulators The rotation and distribution of packages to different lines are performed rapidly and in full stability thanks to the use of manipulating robots. The system uses chain belts divided into sections, each powered by brushless motors to obtain smooth handling and optimise performance. The system is modular and can be configurable with 1, 2 or 4 manipulators based on the required speed levels; it can accept 1 or 2 inputs and process packages individually or by lots containing 2 or more packages. Gantry distribution device Unlike distribution devices with manipulators, this version integrates the distribution elements chasing the packages directly into the structure above the conveyor. Lateral guides Conveyors are equipped with specific lateral guides specifically designed for each product. The most popular ones are roller guides. Guides may be either fixed or adjustable. Adjustable guides can be: Adjusted manually with 2 reference rings for 2 positions, for the single line only. Adjusted manually with the aid of adjustment templates Adjusted manually with the aid of spacers Adjusted with octagon plate with reference templates on each side for independent line conveyors Adjusted with a centralized handwheel for fixed axle base of conveyors for independent lines Adjusted with a centralized handwheel for varibale axle base of conveyors for independent lines Adjusted automatically with a gearmotor. Built-in cleaning system Bundle conveyors may be equipped with a cleaning system consisting of nozzles located inside the body and connected via pipes to a pump that will perform a cleaning cycle launched from the control panel; this feature is useful when handling sugar products that may generate failures due to the stickiness caused by a damaged bottle. Figure 32 Divider with manipulator. Figure 33 Modular belt conveyor for bundles. Figure 34 Infeed dosing conveyor with upperbelt. Figure 35 Gantry type distribution device.

30 30 OCME Complete lines and handling systems Conveyors for secondary containers Continue Roller conveyors Roller conveyors cover a wide range of applications in the handling of secondary packages and differ according to specific needs. The variables that should be considered when choosing the right kind of roller conveyor include the type of product to be handled (form, fragility, content, etc), production speed rate, absence of noise, the fact that it will be installed near accumulated products. Structural characteristics Regardless of their type, the roller conveyors manufactured by OCME have several common features including: A structure frame made of galvanized steel sides with a thickness of 3 mm and an height of 150 mm that make them particularly resistant, thus guaranteeing long life and reducing the number of ground contacts, meeting all hygiene requirements. The high number of mechanical details, including design and commercial factors available in all our conveyors, translates into an easier management of spare parts for the customer. Careful planning and efficiency The special attention given to the design of product flow and the use of cutting-edge automation systems resulted into a careful system planning and optimization, in an attempt to give priority to the mechanical lifespan of moving parts and ensure less energy consumption. OCME can integrate its equipment with detection, marking, distribution and control systems that can easily interface with existing systems based on the customers requirements. OCME offers a wide range of solutions for conveyors and automation systems capable of facing the specificities of ever more complex and branded products as currently required by the market. 36

31 31 Chain-driven roller conveyors For its roller conveyors, OCME uses galvanized rollers with a diameter of 50 mm and a pitch of 75 mm, which are capable of guaranteeing the handling and accumulation of wrapped products in heat shrink cartons and bundles with flaps or flat bottom with a length of at least 230 mm. The maximum production speed rate is 600 mm/sec. The distinguishing manufacturing design that uses a ½ inch bypass chain to drive the rollers enables the machine to produce special conveyors with a reduced pitch of 62.5 mm only that can perfectly handle products of smaller sizes. Flat chain-driven roller conveyors The main feature of this type of conveyor is the fact that it uses a flat chain to drive the conveyors, offering noise-free production lines, and high speed rates of up to 1200mm/sec. The diameter of rollers is 50 mm, while the feed pitch is 75 mm and can handle products with a length of at least 230 mm. This type of conveyor is best suited to meet the needs of multi-line systems and can be used as a product collecting or transfer device. It cannot be used as an accumulation device. A.P.I. chain-driven roller conveyor Designed specifically for product accumulation, this type of conveyor guarantees very low pressure values even at high production speed rates (up to 1200mm/sec) thanks to the sloped profile of the roller s sliding bed. Rollers are driven by a chain that makes it particularly noiseless and it is therefore perfect for multi-line systems. Particularly suited for packaged products in wraparound carton and bundles with flap or flat bottom. It can also be supplied with a reduced feed pitch, with a roller having a diameter of 50 mm and a pitch of 40 mm for products with a length ranging between 160 and 230 mm. Twin side belt system This conveyor is used to distance and carry the packages from the production line to a main collector. The spacing between packages is done thanks to two sections of the belt that run at different speeds Figure 36 Low pressure API chaindriven roller conveyor. Figure 37 Infeed to the palletizer and discard of non-conforming products. Figure 38 Carton distributor from 2 to 1 row.

32 32 OCME Complete lines and handling systems The ideal plant: handling systems within the line Pallet conveyors Carrying full pallets means handling considerable loads, hence submitting the equipment to remarkable stress. Moreover, the automatic selection of defective pallets is fundamental for end-of-line installations. i nfeeding systems for empty pallets and disposal of full pallets, adequately integrated with marking and detection systems can be interfaced with automatic storage system to help manage and analyze the data of the entire system. Based on specifi c requirements, palletizers may be integrated with devices to discard defective pallets and perform operations such as wrapping, hooding, strapping and overlapping of full pallets. Some of the pallet handling, moving and selection systems offered by OCME include: Motorized roller conveyors Motorized chain conveyors Pneumatic 90 diverters Motorized 90 diverters Chain or roller rotating unit Defective pallet control systems Shuttles on rails Laser-guided vehicles Pallet stackers Pallet dispensing systems 39 Figure 39 Pallet handling system with chain conveyor and shuttles on rail.

33 33 Type of conveyor Suited for Laser-guided shuttle Chain rotating device Roller rotating device Defective pallet controller Defective pallet controller robot Shuttle 2-level shuttle Motorized roller conveyor Motorized chain conveyor Pneumatic 90 diverter Motorized 90 diverter Pallet stacker Pallet dispensing system Table key Empty pallets Full pallets

34 34 OCME Complete lines and handling systems Pallet conveyors Continue Manufacturing quality and integration with existing systems The solid structure frame in galvanized steel, the use of quality commercial components combined with a careful mechanical, electrical and electronic planning guarantee the longest lifespan possible and full machine performance. Our conveyors are all equipped with motor-driven components powered by means of an inverter and connected to a central network. This, together with an accurate definition of the machine s design and product flow enables our customers to handle a high number of pallets/hour. Thanks to advanced control and management systems, pallet handling can be optimized on each single conveyor, including speed adjustment based on the type of product being handled, hence exploiting at best the advantages of our systems and equipment. For its end-of-line installations, OCME is able to integrate systems for product labelling, wrapping and traceability by creating an interface with existing management systems. Defective pallet control systems This installation consists of a roller system where a series of pneumatic pressure and tracer pins are used to detect the presence and integrity of the pallet s upper and lower boards, and thanks to mechanical conveyors, it will check the pallet s external blocks and the compartment space under the feeding plane. It is typically integrated with an ejector and stacker for defective pallets. Motor-driven roller conveyors Our roller systems can handle any type of pallet commonly used in production sites, including Euro, Chep, American, disposable, and different kinds of demi-pallet sizes thanks to the following manufacturing features: bypass chain driven conveyor galvanized rollers with a diameter of 89 mm and pitch ranging between 100 or 150 mm Variable length ranging between 1500 mm and 6000 mm Handling weight of up to 3000 kg (individual pallet max kg) Conveyor speed of up to 400 mm/sec (per empty pallet) Figure 40 Chain conveyor. Figure 41 Roller conveyor.

35 Idle roller conveyor Mainly used in end-of-line installations as a pallet drawing bay, it also features idle rollers where pallets are moved by gravity. Chain conveyors Three-way chain conveyors for full pallets and two-way chain conveyors for empty pallets are used to handle 1-inch chains sliding along high-density polystone guideways, thereby minimizing wear. To facilitate the passage from one conveyor to the next, they are also equipped with ring couplings for idle chains that accompany the pallet in order to prevent jolts. Some technical specifications are listed below: Walk-over galvanized plates between chains Variable length ranging between 1500 mm 6000 mm Handling weight of up to 3000 kg (individual pallet up to 1500 kg) Conveyor speed up to 400mm/sec (per empty pallet) Motorized 90 diverter This equipment consists of a 3-way chain conveyor that engages into a motorized roller system equipped with a lifting device. It is designed to divert the pallet by 90 degrees. Its particularly small dimensions and built-in motor-driven cam lifter enable to produce up to 200 pallets/h. It can handle individual pallets of up to 1500 kg. Pneumatic 90 diverter Chains are lifted by means of one or two pneumatic cylinders. This equipment is designed to handle empty pallets or stacks of empty pallets weighing up to 400 Kg. Rotating unit with motorized roller conveyors This installation consists of a motorized roller system mounted on a rotating frame structure with a toothed wheel connected to a gearmotor that can change the rotation direction with a standard angle of 90. However the system can adjust to the needs of any factory layout and customer. It is designed to enable a 360 rotation. It can produce up to 120 pallets/h at a 90 rotation. Chain rotating unit This installation consists of a chain conveyor mounted on a rotating frame structure and is similar to the rotating unit driven by rollers. 46 Figure 42 Full and empty pallet conveyors to robot palletizer. Figure 43 Overlaying pallet conveyors for carton palletizer. Figure 44 Defective pallet controlling device. Figure 45 Roller rotating unit. Figure 46 Motorized 90 diverter.

36 36 OCME Complete lines and handling systems Auriga laser-guided vehicles and shuttles on rails Shuttle on rails Shuttles are particularly suited for complex pallet handling systems with a high number of collection and delivery points. It consists of a shuttle vehicle moving on straight rails, powered by a bus duct, equipped with an onboard PLC unit capable of receiving instructions in real time through data exchanging photocells. This will help achieve the system s top functionality, as it will be constantly updated on the actual needs of the palletising units. The shuttle and the onboard conveyors, whether roller or chain conveyors, are controlled by inverters that will ensure safe handling of unstable loads. Access to production lines is done safely by the laser scanners that control the sides and the heads of the shuttle stopping it whenever it detects unexpected obstacles or impediments obstructing its way. To avoid operating the shuttle to get empty pallets, it is possible to use shuttles with overlaying conveyors where the lower conveyor will hold the empty pallet and the top conveyor will hold the full pallet. There are different types of shuttles that can handle from one to four pallets at the same time. Laser guided vehicles Of all available navigation technologies, laserguided navigation is both the easiest to install and the one that provides greatest flexibility of operation. Hence, OCME has chosen this solution to provide Auriga with a highly reliable drive and route correction system. Laser-guided navigation uses special refl ective targets fi tted to the walls of the shuttle working area, to provide a reference grid for shuttle orientation and steering. In fact, this type of system does not require the installation of any fi xed or movable structures on the plant fl oor. Changes to be made to the layout of the system do not entail any site modifications, but simply require adjustments to the management software; indeed, the vehicles are designed to accept new routes and orders originating from the control system. Unlike other, less flexible navigation systems, automatic laser-guided shuttles can auto-determine the best route to follow to complete a given mission and are aware of the position of all other vehicles in the fleet, so as to avoid collisions. The numerous sensors onboard the shuttle and the system s unique management software logic enable the shuttle to steer clear of any obstacles present in the operating zone. 47 Figure 47 Laser-guided shuttle with two forks.

37 Figure 48 Shuttle on rails for operation with 5 robot palletizers. Figure 50 Automatic battery changing system. Figure 49 Laser-guided shuttle with chain conveyor. Figure 51 Shuttle on rails with two levels for full and empty pallets.

38 38 OCME Complete lines and handling systems Conveyor materials and shapes Figure 52 Bundle accumulation conveyor. Figure 53 Bottle conveyor. Figure 54 Bundle/bottle/package handling conveyors. Figure 55 Bundle/bottle/package handling conveyors. T he wide range of technical solutions for our handling systems has led OCME to carefully select the best brands and technologies currently available on the market. Our conveyors are the result of years of applied research and extensive tests conducted at the company s R&D labs. Today OCME offers the best solution based on the specific production needs, while maintaining and enhancing the specific features of each product being processed, even when it is objectively difficult to handle. The vast range of available technical solutions includes high quality materials suited for general applications and materials designed for special industrial sectors. This page will present an overview of the possible applications of some of our handling devices.

39 39 Figure 56 Sliding profile of chains and belts. Figure 57 Braking conveyors and bundle lifters. Figure 58 Curvilinear bottle conveyors. Figure 59 Conveyors for glass bottles. Figure 60 Conveyors for unstable bottles. Figure 61 Bottle conveyors (straight-line tracts).

40 40 OCME Complete lines and handling systems Research & Development OCME established an Integrapack.it Research & Development lab with the aim to create a centre of innovation and excellence in the design of high level automation lines in order to meet the competitive needs of distribution companies. T he idea of creating the Integrapack.it Research Lab stems from the promoters desire to use and develop the advanced technical know-how that has matured in Emilia-Romagna - known worldwide as highly specialized in the manufacture of automated process and packaging machinery (primary, secondary and tertiary packaging) - in the several fi elds of applications including the Food & Beverage and (vegetable and mineral) Oils sectors. Intervention in the bottling and storage processes, by moving them closer to the locations of consumption, will allow for: greater production fl exibility, with a consequent improvement in the production and distribution chain process; reduced stocks of end products; improved product storage and quality; greater effi ciency and control over the whole process; lower plant management costs; lower shipment logistics costs; lower packaging costs; lower polluting emissions. The objective is the implementation of a Filling and Packaging Line, which is: highly efficient and reliable (in all its components), thus allowing for lower plant management costs (one person per shift will manage the whole filling and packaging line); reduced energy consumption; compact island, less space is occupied; ergonomically designed and safe leading to less accidents at work; flexible and modular, allowing for optimized management of production batches; able to map all process phases with consequent full product traceability; with lower investment costs compared to the current technology used; fully integrated in the cycle of production, logistics and administration. 63 Figure 63 3D CAD planning.

41 41 Advantages for the marketing division T oday nearly every company operating in the consumer goods industry faces the common problem of choosing the right container for their products. A greater environmentally friendly awareness shown by consumers is leading to a reduction of the weight of primary containers and wrapping materials, alongside the need to diversify one s offer, which are generating a certain degree of instability and an objective diffi culty associated with dealing with certain products, at least when using traditional systems. OCME has been facing these issues for years and has been working on several fronts to provide companies, and in particular the market, with the maximum level of flexibility regarding the strategic choices of the shape of containers and the materials to be used. Of course, conveyor lines should follow the direction taken by filling, packaging, and palletizing machine and logistics that have gradually achieved levels of excellence in terms of operating flexibility. The quality of the end-product plays a central role for OCME packaging systems. Belts, conveyors and all other devices that handle primary containers, secondary packages and pallets follow specific requirements to prevent abrasions and frictions, thus preserving the product s aesthetic appeal and a quality level perceived by the market and the end-user. Advantages for the administration division O CME operates as a provider of turn-key lines, offering a direct, reliable and competent contact for its customers. Almost 60 years of activity are the demonstrable proof of its business continuity in the market and its ability to develop installations, products and services that have always achieved the goals set by customers. At OCME, we put ourselves in our customers shoes. We would like to be free to change and adjust our products to ever-changing needs. This is why our technology offers a unique level of fl exibility. Unlike the past, today we can save the technical investment initially made and use it in case it becomes necessary to extend, integrate or redesign a production plant. This is possible thanks to the application of innovative planning methods, together with open IT systems, and machines and conveyors that can self-adjust to the tasks that may change over time. A major issue for company managers is safety. For OCME safety planning is a crucial step when designing a production line, together with its conveyors and equipment. In order to obtain the maximum level of safety, both active and passive protection devices and safety guards are installed, we supply operator manuals and deliver dedicated training courses to instruct operators on how to work safely and be informed on safety provisions that could protect their health and lives. Even maintenance activities, performed by highly skilled and trained staff, are conducted according to anti-injury protocols, and in fact, reports show a continuous improvement in eliminating injuries at work for any type of task.

42 42 OCME Complete lines and handling systems Environmental compliance: an opportunity to distinguish yourself at ethical level e very part of a packaging and storage line can play its part in reducing overall energy consumption. This means that any device, if well-designed, can reduce its impact on the environment and help the company save money. Basically, a modern OCME line operates on two fronts when it comes to minimizing its environmental footprint and save of energy bills: less raw materials and reduced power. Today s consumers and the distribution chain require lighter containers to avoid waste of raw materials or, for some products, the possibility to manage disposals. OCME conveyors are designed to manage these types of products in an effi cient way. As for energy saving, OCME is developing machines and conveyors that require gradually less power and rely on a more extensive use of kinetic energy. OCME has been dealing with the OCME WorldCare project for years, a business educational project aiming at proactively intervening in favour of the environment by means of differentiated waste collection and careful use of power and raw materials in general. Project principles include raising awareness among designers about environmental protection and the depletion of resources. The aim is to implement new categories of systems, the performance of which develops hand in hand with their ability to guarantee an ecologically sustainable development. Corporate environmental respect programme All rights reserved. Registered trademarks belong to their legitimate owners. OCME may not be held liable for any responsibility arising from the content of this document, and reserves the right to change technical data, characteristics, and descriptions without prior notice. OCME may not be held liable for damages arising from the lack or inaccuracy of the information contained in this document.

43 All the OCME technologies dedicated to your sector One of the characteristics for which OCME is renowned for in the market is the company s flexible approach to customer needs. We believe that each sector must be followed with specific care, because each has specific needs. For this reason, our staff of professionals is specialised in responding to the needs of every single customer, based on the unique characteristics of each sector. Beer Mineral water Soft-drinks Wines and spirits Food Edible oils Tissue Petrochemicals Pharmaceuticals Products for personal and home care

44 MOVING IDEAS This technology is part of the IntegraPack.it Project OCME S.r.l. Via del Popolo, 20/A Parma (Italy) Phone Fax OCME UK Ltd. King John House, Kingsclere Park Kingsclere - Newbury Berkshire RG20 4SW (UK) Phone: Fax : [email protected] OCME AMERICA CORPORATION 5300 N.W. 33rd Avenue, Suite 105 Ft. Lauderdale, FL Phone: Fax: [email protected] OCME Complete lines and handling systems Our task as providers of packaging and filling technology and logistics is not only to install a system, i.e. solve an immediate problem. We rather believe our role is to provide a vision of the future of production in the factories of the fast moving consumer industrial sector and propose solutions that are ahead of the times. This is at least what we have been doing since This document presents our experience and our technologies applied to complete lines for the fast moving consumer industry. As any OCME product, systems, devices and services offered by the company throughout the system s entire life cycle are designed to run intensively and provide customers with solid support to the strategic choices they intend to implement. Today companies of the fast moving consumer sector have a great opportunity to differentiate themselves and increase their competitiveness by aiming at efficiency and integrated automation of the whole productive section, ranging from the filling to the handling of pallets with automated guided vehicles, thanks to OCME technology. GraphoServiceParma Tutti i diritti sono riservati. All rights reserved. CL-HAN-EN Rev OCME FRANCE 42 avenue Montaigne Paris Phone:+33 (0) [email protected] OCME Packaging Equipment (Jiaxing) No.289 Mu Yang Road, Jiaxing Economic Development Zone, Jiaxing City, Zhejiang Province, P.R.China Phone: Fax: [email protected] OCMEXICO Embalaje, S. de R.L. de C.V. Homero 425 Desp. 2, Torre B Col.Chapultepec Morales México D.F., CP Phone: ext. 103 Fax: ext [email protected]