Sealing System has delivered, installed and integrated a complete packaging and palletizing solution at Danish Bottling. Workflows have been automated and streamlined.
Danish Bottling is a major player in the manufacture of soft drinks. Beverages are produced in large quantities and with great variation, e.g. soft drinks, energy drinks, mineral water, private label and flavored water - for the Danish and the European market.
The old production plant
Parts of the previous production was based on manual work, and only part of the production had already been automated.
Why Danish Bottling needed a new solution
Danish Bottling would like to become more efficient to be able to produce more products and achieve a higher capacity. A higher capacity in the same space and with the same crew, would mean a greater profit per. unit. So, the goal was to run more products through the system – for less funds.
The new packaging and palletizing solution
The solution for Danish Bottling consists of two packing and palletizing lines. A palletizer and a robot solution for packing and palletizing ½, 1 and 2L disposable bottles.
One line consists of Sealing System’s own Ip-4 Greenline - a fully automatic palletizer able to palletize large quantities at high speed. This version has two inlets. It can palletize from two packing lines and for two different pallets via a transfer trolley. The palletizer has a throughput of 21,000 ½L bottles per hour. The solution includes a transfer trolley and pallet conveyors. The pallets run on conveyors with built-in buffering space.
Green profile - the palletizer is driven by servo motors instead of compressed air, which saves on energy consumption.
Robot handling and palletizing
In this line, the bottles are transported on product conveyers to a KUKA handling robot which packs the bottles in trays, using a vacuum robot tool. The bottles are then transported in the tray to a shrink-wrapping machine, which wraps the tray with bottles in foil and has a product label affixed.
The bottles are then palletized by a KUKA palletizing robot, using a sliding hand on quarters or EUR pallets.
Result and customer satisfaction
The result of the new packaging and palletizing solution
Capacity has doubled. Twice as many products run through the new solution.
Significantly faster changeover between product types. Changeover of production is significantly faster than before, when a changeover would take between 30 and 60 minutes. Today, the changeover is a simple push of a button, which may also be used to adjust other settings such as the side guides.
Transfer trolley. Pallet conveyors and transfer trolleys minimize truck driving.
Buffer conveyors. Buffer capacity has been integrated on the line’s product and pallet conveyors to avoid halts in production.
Higher degree of automation.
Energy saving / green profile. Servo motors result in energy savings.
A good and intelligent solution and nothing like the solution the customer had in mind from the start.
Going for greener profile was a logical move, and the servo motors use less power than a traditional pneumatically driven system. It also means that the spare parts last longer.