[Case study] Complete line for packaging multi-reference crisp tubes

Context

Our client, a snacking product manufacturer, wanted to invest in new production tools in order to modernize its current packaging and wrapping equipment and increase its production capacities.

To meet the needs of the different end points of sale (large and medium-sized stores), the client must mix the different references of its products within the packaging box.

Technical characteristics of the products:

• Vertical cardboard tube
• 3 case formats with 4 glued corners
• Packaging of 15, 25 or 35 tubes per case

Solution proposed and supplied by MG Tech

In order to meet the customer's requirements, MG Tech designed and supplied a complete line for packaging multi-reference crisp tubes, taking care of all the packaging stations, namely:

• The shaping of the 4-corner glued cases with two Ecobox case formers with horizontal magazine;
• The automated top-load case packing, in two lines, of the cardboard tubes in the previously formed cases. Thanks to the Delta robot, the crisp tubes are placed in the cases in batches of 5 to form 3, 5 or 7 rows depending on the loading plan of the case;
• The mixing of product references within the cardboard cases. At the exit of the case packers, the tube cases arrive on 3 lines (two lanes supplied automatically from the case packers and one lane supplied manually), the tubes are removed from their cardboard case to be placed, by reference, on conveyor lines. Depending on the packaging plans, the robots refill the cardboard cases with multiple references (e.g.: 5 tubes reference A, 10 tubes reference B, 10 tubes reference C);
• The conveying of products, on the ground or in the air, between the process machine and the case packers, between the case packing stations and the mixing machine or the palletizing area.

Technical characteristics of the equipment:

• Ecobox case forming rate: up to 8 cpm / 2 formats
• Top load case packer rate: Products 120 ppm / Cases in 15 and 25 i.e. 8 and 4.8 cpm
• Mixing machine rate: Up to 10 cases / min at the output

The advantages of the MG Tech solution

The case packer for mixing references was designed to manage all the product mixes (3 different flavors) desired by the customer. A single setting via the HMI allows the mixing order to be modified. The automation of product mixing saves significant time compared to manual operations. This allows the production rate to be maintained and productivity to be increased.

MG Tech offers modular and compact equipment that integrates perfectly into existing environments.

All equipment is automated. Lanes A and B of the mixing case packer are automatically fed directly from the top load case packers. Format changeovers on the case formers and top load case packers are fully automatic and do not require any additional tools.