Wraparound case packers installed for Arnott’s

A custom-built, end-of-line packaging solution consisting of four wraparound case packers has been designed, built and installed by Cermex for biscuit manufacturer Arnott’s. The packaging solution requirements were to move from manual to automated case packing as well as changing the company’s secondary packaging from regular slotted containers (RSC) to wraparound blanks. A quick start-up of four production lines simultaneously while maintaining the integrity of the product was essential and the solution needed to be able to accommodate frequent form changeovers. An exponential increase in speed to 12.5 cases/min and a maximum pack speed of 175 packets/min was also required.

Primary packaging handled at Arnott’s consists of rectangular or pyramid-shaped cartons, or flow-packed plastic trays of round biscuits. The project involved controlling product conveying and collation, while preventing the flow-packs from rotating. Gripping systems were installed with the capacity of adapting to 58 different SKUs packed into 32 different case sizes and formats.

Project Engineer for Arnott’s André Spoor was in charge of the project. He said the two most crucial aspects were: “The large number of SKUs and the fact that we previously packed our product in RSCs and these all had to be changed to wraparound cases as part of the project.”

Cermex installed three identical multifunction WB45 wraparound case packers and one traditional wraparound case packer for a slower line. Two robots were integrated per machine in order to ensure operation at the required speed and optimum machine life span. Each robot runs at a reduced nominal speed so that the products do not endure too frequent accelerations and decelerations. Cermex chose robots manufactured by Fanuc for the task.

The products are transferred 90° onto a collation table, by a small pick and place module, in order to prevent the flow-packs from rotating. The table is made up of front and rear servo-driven brackets to support the batch.

Loading is started by robot one and finished by robot two, with smooth movements so that loading can be carried out without using a funnel. The gripping tooling heads used are composed of 30 to 50 mini suction cups, so as to constantly maintain the vacuum gripping, even if one of the suction cups loses its adherence with the product. This is important for flow-packs as gripping film is difficult.

Robotics contributed to simplifying the solution and reducing the number of parts and adjustments so that the Cermex WB45 could fully meet Arnott’s requirements. In particular, the robot tooling common to several formats helps to significantly reduce the changeover time in order to achieve the 25 minutes maximum.

The absence of multilane guides on the product infeed also reduces setting requirements. Furthermore, the robot heads all weigh less than a kilogram; a reduced mass which considerably facilitates changeover.

The project was managed by Cermex in the design stage by means of 3D modelling and the machines were trialled prior to dismantling and dispatch. “During the project we were well supported by Cermex. As we look to maintain and further develop the machine capabilities for new products in the future it has been pleasing to see that this support has not diminished after the commissioning and sign-off of the machines,” concludes Spoor.