Efficient conveyor and turning technology for a flexible packaging process

Task

A manufacturer of office supplies was faced with the challenge of transporting packs of cardboard folders (packs of 3 or 5 with a weight of up to 2.5 kg) efficiently and reliably from production and packing to the shipping facility.

Two different packaging scenarios had to be taken into account: direct packaging in cardboard boxes and film packaging via an upstream automatic packing machine. The system had to reliably handle cycle outputs of 8 or 14 packs per minute in three-shift operation and at the same time ensure gentle product handling and safe integration.

Solution from mk

The provided system is based on continuous conveyor technology that covers both packaging variants in one line. In the standard case, the folder packs are transported upright via an approximately five metre long belt conveyor with lateral roller guides directly to the downstream packaging station.

For film packaging, the products are specifically ejected from the main flow and fed to an automatic packing machine. Here, an integrated turning machine ensures that the products are transferred in the correct position: A turning star picks up the vertically positioned packs, turns them 270 degrees and places them flat on a timing belt conveyor equipped with cams. From there, the packs are transferred via a roller conveyor with pusher onto another belt conveyor, which then feeds the packs precisely into the automatic packing machine.

After shrink-wrapping, the packs are returned to a belt conveyor with a swivelling maintenance passage and are discharged from the automatic packing machine. They are then returned to the conveyor line: The products are once again transferred via a roller conveyor to a timing belt conveyor and fed to a second turning station. There, another turning star rights the packs again and returns them to their original, vertical position on the main conveyor.

The complete system, including the control cabinet and controller, was installed as a turnkey solution ready for connection. All turning stations and feeders are fully enclosed to protect the operating personnel and are equipped with safety-monitored access doors.

Customer benefits

High process reliability combined with flexible handling of both packaging variants
Efficient material flows thanks to automated infeed, outfeed and turning of products
Reliable and continuous three-shift operation with a consistently high cycle output
Gentle handling of products in the correct position throughout the entire process
Increased workplace safety and easy maintenance access thanks to a well-designed system layout