Case study - Complete line for packaging sealed trays for the ready meal market

Context

Our client wanted to replace two existing packaging lines with new equipment by receiving the current production capacities of these 2 lines on a single one. The line had to include different functionalities: wrapping trays with compact cardboard, erecting cardboard boxes, packing wrapping trays in the boxes and palletizing automatically boxes on pallet. The manufacturer wanted to invest in equipment that was easy and simple to use by operators. He also needed machines that allowed simple and repeatable format changeovers.

Solution provided by MG Tech

The complete line supplied by MG Tech includes all the functions of an end of packaging line, namely: a wrapping machine for sealed trays with pre-glued compact cardboard, an Ecobox case former for the shaping of 4-corner glued boxes, a top load case packer for packing trays in cardboard boxes and finally the robotic palletizer to place automatically open boxes on pallets.

Technical features

Sealed trays and cases:

• 2 different formats
• 2 case-packing lines
• Speed: 140 products/min or 70 products/min/lane

Cases with 4 glued corners:

• 4 different formats
• 35 cases/min

Pallets:

• 1 format
• 15 pallets/hour

Advantages of the line proposed by MG Tech

The complete solution designed and manufactured by MG Tech to meet the need for packaging sealed trays of prepared meals offers many advantages, including:

• A single point of contact for the entire project: the different equipment of the line has been studied and designed with the same aim in mind, so the machines integrate perfectly with each other and communicate more easily. From one machine to another, the speed rates are respected. This is a major advantage for the customer who does not need to act as a relay between several different suppliers and a considerable time saving in project management.
   
• Fast and repeatable format changeovers: whether for cases or cardboard boxes (former and case packer), format changeovers on the packaging machines are very simple and quick to perform (<5 min for the former and case packer and <10 min for the palletizer). Each adjustment has been designed to be ergonomic and simple (indexing finger, color code, handwheel for magazine adjustment, tool change by SMED kit).
   
• Simplified line operation accessible to all types of operators: thanks to colored LEDs on the machines, machine faults or stoppages are easily identifiable and clear instructions are displayed on the HMI screens.
   
• Machine connectivity: the machines are connected and communicate with the customer's ERP system via an OPCUA system.
   
• Reduced footprint: despite the complexity of the packaging line, the equipment has been ergonomically designed to limit the footprint (for example, the cartoner has 4 cardboard die-cutting magazines per lane to limit the footprint).

How does our solution fit into the changing needs of the market?

MG Tech is specialized in the design and manufacture of machines for the end of packaging lines. For many years, MG Tech has had real expertise in supplying complete lines that combine different packaging functionalities. This saves time and money for manufacturers who only deal with a single contact. In addition, the automation of the various packaging stations allows our customers to achieve a considerable productivity gain (higher rate, simple and rapid format changes, controlled space requirements, etc.).