Ergonomic sorting line increases efficiency

Task

A manufacturer of customised foam packaging solutions produces die-cut foam parts for protective, transport and presentation applications, such as suitcase or insulation inserts. The components vary greatly in shape and size, but weigh a maximum of 1 kg each.

The customer needed an ergonomic sorting line that would enable the reliable separation of usable parts and punching waste. The aim was to make the usable parts available for further processing and at the same time to collect the offcuts cleanly for recycling. Particular attention was paid to reducing the strain on employees while maintaining a high throughput in two-shift operation.

Solution from mk

mk implemented a multi-stage sorting and conveying system that meets all of the customer's requirements. Firstly, the punched foam parts are transferred to a generously dimensioned sorting table with a stainless steel worktop via a belt conveyor provided by the customer. Here, manual pre-sorting is carried out: Useful parts are placed on the downstream sorting belt, while the offcuts drop onto a disposal belt below via an integrated chute.

The pre-sorted punched parts are transported to six ergonomic manual workstations on the subsequent 10-metre-long sorting line. This is where the detailed sorting takes place: Residual waste is disposed of via side-mounted chutes onto the belt conveyor below. The usable parts are removed and prepared for further processing. The sorting belt and disposal belt consist of robust GUF-P 2041 belt conveyors with stainless steel guide plates on both sides. The workstations also have integrated compressed air connections.

At the end of the line, the collected punching waste is transported into a recycling container via an ascending conveyor. The conveyor is a GUF-P 2041 belt conveyor with welded-on transverse cleats and is mounted on swivel and fixed casters, making it mobile.

The entire system is antistatic, with complete electrical installation including system control on a directly mounted control cabinet.

Benefits for the customer

• Flexible integration: modular system can be easily integrated into existing production facilities
• Efficient sorting: fast and reliable separation of usable parts and punching waste
• Ergonomic workstations: reduced strain for employees and short distances
• Sustainable waste management: clean collection of waste for recycling

Used products

> Belt conveyor GUF-P 2041
> Workstations