[Case study] Wrap case packing for trays in cases with ledges (ready-to-sell)

Context

As part of the implementation of a new packaging line, our customer asked us to study the automation of case packing for thermoformed trays.

Technical features of products

• Product type: cheese sealed trays (3 different formats)
• Case type: case with joined ledges ready to sell (2 different formats)

Constraints to take into account

Some constraints, imposed by our customer, had to be taken into account in the project:

• Implementation of the machine: limited space in the existing area
• Respect of the product and case integrity
• Control of the product and case conformity:
  • Presence of labels located under the tray
  • Presence of labels located on the case
  • Control of the correct number of products packed
• Respect of production rates: up to 110 trays/min and 7 cases/min
• Ergonomics of workstations for operators
• Full automatic format changeovers
• Supply and integration of peripheral equipment (case labeler)

Solution designed and provided by MG Tech

To meet the need for automated case packing, MG Tech designed and manufactured a wrap case packer. Our automatic case packer is made of different stations:

• Conveyors for collecting trays from the labelling machine;
• A control of product through barcode reading. Non-compliant product are evacuated without stopping the machine;
• A tracking conveyor allowing the trays to be transferred to the Delta robots, giving the exact position for gripping in tracking mode;
• An ergonomic horizontal blank magazine with large autonomy;
• A case packing and transfer station. As it moves forward, the case is formed, the products are packed inside using Delta robots, then it is glued and closed. The labeling of the cases is also carried out at this stage.

The main advantages of MG Tech solution

All the equipment provided by MG Tech offers a lot of benefits:

• The design of conveyors ensures the transfer of large trays ;
• The machine includes a system of control for non-compliant products;
• No preparation of products is required before packing (no grouping, batching or accumulation);
• Delta robots ensure a great packing flexibility;
• Format changeovers are automatic (excluding changing grippers to be done manually).