Palletising Depalletising - Mectra - Palettising depalettising … scatolifici... · ·...

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PalletisingDepalletising

difference

w w w . m e c t r a . i t

Palletisation, conveyors and logistic solutions for can the making industry

Sensible solutions to increase added value for highly specialised palletising and handling technologies


difference


Sensible solutions to increase added value for highly specialised palletising and handling technologies

Index

Leaders in the can making industry challenges 5

A specific capacity in the can-making industry 6

Can conveyors 8

Palletisers for shaped and/or unstable cans 10

Sweep-off palletiser for cylindrical cans 12

Sweep-off palletisers for tinplate, aluminium, plastic and cardboard cylindrical cans 14

Palletiser with magnetic plate for cylindrical cans 16

Palletiser/depalletiser with magnetic plate for cylindrical cans 18

Palletisers/depalletisers with magnetic plate, two column framework and steady pallet for cylindrical cans

20

Palletisers with magnetic plate for cylindrical cans 22

Palletising robot with magnetic plate - payload 300 Kg 24

Palletising robot with magnetic plate - payload 160 Kg 26

Palletisers comparative table 28

LGV shuttle 30

Automatic shuttle for pallets handling on rails 32

Pallets conveyors 34

Safety at work, manufacturer’s and buyer’s risks and responsibility 36

5Palletisation, conveyors and logistic solutions for can the making industry

Nowadays, manufacturers of tinplate or alu-minium packages have to face a very unstable market compared to some years ago, with new leaders and fluctuations. Many problems found in industrial sectors, below the value chain to the distribution chains, lay on manufacturers of packages, who have to react in the best possi-ble way in order to keep or improve their com-petitive advantage. The trend during the last years has been to reduce the weight and the-refore the thickness of packages, owing to a re-duction of both the raw materials cost and the environmental impact. It is difficult to process these types of packages as they can be easily damaged at different stages of the production cycle. That is why it is very important, for the future of production technologies in the can-making industry, to be able to efficiently run boxes, cans (even 0,1 mm thick ) and aerosol bottles. However, this is not the only challenge that the can-making industry has to face. Any

company has its commercial policy according to which there would be two kind of demands, depending on the production volumes and the range of items to work. On one hand, there are manufacturers specialized in productions of small and medium quantities with a wide range of items, who need high flexibility and quick or prompt changeovers. On the other hand, the-re are companies with a very high production and less packaging formats or maybe only one kind of package, which require high-level well-running devices for all the line. These different needs originated from two opposite causes of a new globalization market; small productions for private-label, test-area or, for localized pro-ducts and centralized large-scale productions, to reach economies of scale. Whichever stra-tegy a manufacturer can choose in the future, it is clear that, to be a leader, he will have to apply to production technologies able to fight in mar-kets still to be regulated.

Leaders in the can-making industry challenge

I N T R O D U C T I O N

6

www.mectra.it/thislink


A specific ability in the can-making industry

A wide range of systems to guarantee the best outcome in any production field. Mectra palle-tisers/depalletisers for the can-making industry represent the state-of-the-art in the technology for this sector.

High flexibility and potential to work with diffe-rent products or patterns. Palletising and depal-letising robots are the ultimate solution for flexi-bility and use.

1 Standard De/Palletisers 2 Robot

Highlight

The specific features of packages, materials and production variables in the can-making industry, need the application of customized technology. For this reason, Mectra is always involved in developing solutions expressly designed for this purpose.

C O M P L E T E L I N E S


The real added value in a production line is the in-terconnection between the different production steps. Mectra’s conveyors have been expressly de-signed for this scope thanks to a long and specific experience.

In order to reach the highest level of automation for a production line in the can-making indust-ry, it is necessary to consider the handling of full pallets from and to the store with the help of an integrated laser guided vehicles system.

The pallets conveyors have to guarantee the in-terconnection between the end of line and the pallets store. Therefore, they have been designed to facilitate the handling of products in the best possible way and to comply with the layout spe-cifications.

3 Conveyors 4 LGV Shuttles 5 Pallets conveyors

Safety

Mectra endorses the strictest directives as regards safety in workplaces. This is a crucial guarantee for both workers and companies which, in this way, can not run any risk.

Assistance

Assistance, after-sales and spare parts dept. support any kind of installation for its whole life in order to guarantee the best efficiency and benefit in time.

Efficiency

The efficiency of Mectra systems and lines are by default very high.

Output

Every line has been designed to guarantee the achievement of the required output level, considering the kind of product to be processed.

8 Palletisation, conveyors and logistic solutions for can the making industry

Can conveyors

C O M P L E T E L I N E S

• Stainless steel or plastic slat conveyor• Cable conveyor• Modular belt conveyor• Chain conveyor • Plane magnetic conveyor for tinplate cans • Magnetic elevator/lowerator conveyor• “Merry-Go-Round” buffering device

For unstable products, we can foresee magnetic tracks underneath the aforementioned conveyors. These tracks allow a reduction of unsteadiness and a higher handling ease and speed.

Highlight

Every product is unique and its handling requires specific devices. Even when there is a differential production, the quality of cans conveyors makes a big difference on the efficiency of the whole production line.


Modular chain conveyorCan-bodies alignment lineMagnetic elevatorChain conveyors


Automatic high-loading palletiser for shaped and/or unstable tinplate, aluminium, plastic and cardboard aerosol cans.The layer pre-formation is made by a row pusher (the number of rows may change according to the line output and the size).The layer transfer on the pallet is made by a sweep-off system, with motorised or idle bar. Output up to 2/2.5 layers per minute.

P A L L E T I S I N G F O R T H E C A N M A K I N G I N D U S T R Y

Palletisers for shaped and/or unstable cans

Palletiser with rows pre-formation and sweep-off layer transfer system, movable palletMT 567/S

MT 567


Automatic high-loading palletiser for shaped and/or unstable tiplate cans.The layer pre-formation is made by a row pusher (the number of rows may change according to the line output and the size). The layer transfer on the pallet is made by a magnetic head. Output up to 3/3.5 layers per minute.

Palletiser with rows pre-formation and layers transfer with magnetic plate, movable palletMT 567/M



Sweep-off palletiser for cylindrical cans MT 569

Automatic high-loading palletiser for tinplate and aluminium cylindrical cans. There is also the possibility to insert handling systems for pallets, layer pads and frames (iron, wood and plastic). Sweep-off layer transfer system, complete with devices for the layer guided forma-tion. Output up to 7 layers per minute.

Highlight

A brand new re-designed machine, studied for low or medium productions in the can-making industries; it offers an easy access to the operator, very low maintenance impact, wide range of commercial components. High design flexibility.


Layer pads and frames movable bin system

Layer sweep carriage

View for stepless “no-voids” system



Sweep-off palletisers for tinplate, aluminium, plastic and cardboard cylindrical cansMT 566

Highlight

A brand new re-designed machine, studied for medium or high-medium productions in can-making industries; it offers an easy access to the operator, very low maintenance impact, wide range of commercial components. High design flexibility.


Automatic high-loading palletiser for tinplate, alu-minium, plastic and cardboard cylindrical cans with devices for the layer guided formation. The layer transfer on the pallet is made by a sweep-off system. Output up to 5 layers per minute. This model has the possibility to feed layer pad and pallet by hand (se-mi-automatic version).

Automatic high-loading palletiser for tinplate, alumi-nium, plastic and cardboard shaped packages. Layer pre-formation made by multiple rows pusher (they may change according to the line output). The layer transfer on the pallet is made by a sweep-off system. Output up to 4 layers per minute.

Palletiser with layer pre-formation and sweep-off transfer system, movable pallet

Palletiser with layer pre-formation and sweep-off rows transfer system, movable pallet

MT 566

MT 566/F


P A L L E T I S I N G / D E P A L L E T I S I N G F O R T H E C A N M A K I N G I N D U S T R Y

Palletiser with magnetic plate for cylindrical cansMT 568 DOPPLER/P


Automatic high-loading palletiser for high productions, for tinplate cylindrical cans.There is the possibility to insert handling devices for pallets, layer pads and frames (iron, wood and plastic). This model can be equipped with different lifting heads, vacuum type or by grips for non-magnetic materials such as aluminium, plastic and carton.Output up to 5 layers per minute.



Palletiser/depalletiser with magnetic plate for cylindrical cansMT 568 DOPPLER/DP

Highlight

This machine is the best solution to work as buffer between the cans production line and their filling. We can summarize in three steps its main applications:

STEP 1: Taking up an overproduction from the can-making dept. as to the filling area.

STEP 2: Complete taking up of can-making production in case this area is stopped or in troubles.

STEP 3: Depalletising cans previously palletised or pallets loaded by hand by the operator in case the can-making department is in troubles.


Automatic high-loading palletiser/depalletiser designed for high productions for tinplate cylindrical cans.There is the possibility to insert automatic handling systems for pallets, layer pads taking/removal and frames taking/removal (iron, wood and plastic). The change operation from Palletiser to Depalletiser can be automatic. Output up to 4,5/5 layers per minute.



Highlight

Thanks to its great design flexibility, this machine can be easily fitted to any layout. It can be completely manual or automatic. Adjustable to very strict areas. High CE conformity owing to the two column framework.

Palletisers and palletisers/depalletisers with magnetic plate applied to a telescopic trolley with vertical and horizontal movement.Low-loading in order to work with steady pallet. Palletiser output up to 3,5 layers per minute; palletiser/depalletiser output up to 2,5-3 layers per minute.

Palletisers/depalletisers with magnetic plate, two column framwork and steady pallet for cylindrical cansMT 562/P MT 562/DP


MT 587/ML

Palletisers with magnetic plate for cylindrical cans

Magnetic head palletiser for tinplate cylindrical cans. The machine can be equipped with va-cuum or gripping head for cans made of non-magnetic material such as aluminium, plastic and cardboard. Output up to 3,5 layers per minute.

Palletiser equipped with two or more conveyors, in order to guarantee the palletisation of different products at the same time with layer preformation and layer transfer system by magnetic head for tinplate cylindrical cans. The machine can be equipped with vacuum or gripping head for cans made of non-magnetic material such as aluminium, plastic and cardboard. Output up to 2 layers per minute.

MT 587

All MT 587 machines are equipped with a pantograph and can be realized in semi-automa-tic or automatic version thanks to the insertion of handling systems for empty pallets and automatic positioning systems for layer pads. Low-loading product infeed, positioning on steady pallet and horizontal layer transfer by a trolley on wheels controlled by gear motor and drive belt and vertical transfer through a system equipped with wrapping belt. The MT 587 models can be equipped with different lifting heads, vacuum type or by grips for non-magnetic materials such as aluminium, plastic, cardboard.

MT 587, MT587/ML, MT 587/F, MT 588


23

MT 588


Palletiser with layer pre-formation by a multiple rows pusher and sweep-off layer transfer system. The ma-chine can be equipped with vacuum or gripping head for cans made of non-magnetic material such as alu-minium, plastic and cardboard. Output up to 3 layers per minute.

MT 587/F

Optionals for automatic changeover

Palletiser/depalletiser

Palletiser/depalletiser with pantograph in semi-auto-matic or automatic versions thanks to the insertion of handling systems for pallets and automatic taking systems for layer pads. Low-loading product infeed, positioning on steady pallet and horizontal layer transfer by a trolley on wheels controlled by gear motor and drive belt and vertical transfer through a system equipped with wrapping belt. Output up to 2.5/3 layers per minute.

24


Palletising robot with magnetic plate - payload 300 kg. With its solid and strong frame, it can work with heavy weights. It features reduced overall dimensions and a large workplace around its rotating cen-tral axes, up to 360°. In this way, the robot can also reach the areas behind itself.Flexible and safe, the palletising robot can take multiple palletising positions; the system can be inserted into existing lines and the anchor base can be supplied with specific heights. Reliable, long-lasting and silent system with a guaranteed short-term return of investment. The software

allows to easily programme even elabo-rate palletising cycles. The magnetic head is expressly designed and is composed of an electro-pneumatic layer release grid. It can be equipped with a set of suction cups and venturimeters for the taking and placing of layer pads and side grips for taking the single empty pallets. The maxi-mum output is 6 layers per minute which can change according to the construction shape of the robotic isle. The anthropo-morphic arm is suitable for a magnetic head but also for other pick and place to-ols suitable for other kind of packages.

Highlight

Thanks to its max. speed of 6 cycles/min. (changeable), Robot Kuattro X/PM is the optimal solution to process different medium-high productions.

Compacting device included in the head for unstable products.

Independent centring unit fit to compact the layer previously positioned and the layer pad, in order to have a perfect squaring of the palletised loading.

Magnetic layer pick-up device, also vacuum or gripping types are available.

Palletising robot with magnetic plate – payload 300 kg

R O B O T

KUATTRO X/PM

26


Palletising robot with magnetic plate - paylo-ad 160 kg. With its solid and strong frame, it can work with heavy weights, it features redu-ced overall dimensions and a large workplace around its rotating central axes, up to 360°. In this way, the robot can also reach the areas behind itself. Flexible and safe, the palletising robot can take multiple palletising positions; the system can be inserted into existing lines and the anchor base can be supplied with specific heights. Reliable, long-lasting and silent system with a guaranteed short-term return of investment. The software allows to

easily programme even elaborate palletising cycles. The magnetic head is expressly desig-ned and is composed of an electro-pneuma-tic layer release grid. It can be equipped with a set of suction cups and venturimeters for ta-king and placing the layer pads and side grips for taking the single empty pallets. The maxi-mum output is 6 layers per minute which can change according to the construction shape of the robotic isle. The anthropomorphic arm is suitable for a magnetic head but also for other pick and place tools suitable for other kind of packages.

Highlight

Highly flexible pattern composition and standard operations. High speed: 6 layers per minute. Easily adjustable in case of modifications in the production line.

Palletising robot with magnetic plate – payload 160 kg

R O B O T

KUATTRO S/PM


Anthropomorphic robots are used as palletisers and depalletisers, in this way there is a higher ope-rative and design flexibility as regards traditional technologies. Thanks to this feature, it is possible to rely on the software for any problem related to

changeover or other palletising parameters. Parti-cular requirements or project restrictions can be easily managed by robotic technology. Mectra proposes to the can-making industry its robots Kuattro with payload from 160 to 300 kg available

in different set-ups and with different optionals to efficiently run any kind of product. Robots Kuat-tro with laser guided shuttles or shuttles on rails achieve today the highest possible automated level.



Palletisers comparative table

Suggested Applicable Not suggested/not applicable

Palletiser for shaped and/or unstable cans

Sweep-off palletisers for tinplate, aluminium, plastic and cardboard cylindrical cans

Palletiser/depalletiser with magnetic plate for cylindrical cans

Palletiser (palletiser/depalletiser) with magnetic plate, two columns framework and steady pallet for cylindrical cans

Sweep-off palletiser for cylindrical cans

MT 567/S MT 567/M MT 569 MT 566 MT 566/FMT 568DOPPLER/P

MT 568 DOPPLER/DP

MT 562/P MT 562/DP MT 587 MT 587/ML MT 587/F MT 588 KUATTRO X/PM

KUATTRO S/PM

General features

Machine PAL PAL PAL PAL PAL PAL PAL/DEPAL PAL PAL/DEPAL PAL PAL PAL PAL/DEPAL ROBOT ROBOT Machine

Low speed Low speed

Medium speed Medium speed

High speed High speed

Loading HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH/LOW

LOW/ HIGH

LOW/ HIGH

LOW/ HIGH

LOW/ HIGH

LOW/ HIGH

HIGH/LOW LOW Loading

Magnetic head a a a a a a a Magnetic head

Quick changeover/product


Layers/min. 2/2,5 3/3,5 7 5 4 5 4,5/5 3,5 2,5/3 3,5 2 3 2,5/3 5,5 ÷ 6 5,5 ÷ 6 Layers/min.

Products

Cans and boxes Cans and boxes

Unstable cans Unstable cans

Reduced height cans

Reduced height cans

Aerosol cans Aerosol cans

Full cans Full cans

Aluminium cans

Aluminium cans


Palletisers with magnetic plate for cylindrical cans

Palletising robot with magnetic plate

* The above mentioned values can change according to the type of can, loaded pallet height, type of pallet.

MT 567/S MT 567/M MT 569 MT 566 MT 566/FMT 568DOPPLER/P

MT 568 DOPPLER/DP

MT 562/P MT 562/DP MT 587 MT 587/ML MT 587/F MT 588 KUATTRO X/PM

KUATTRO S/PM

General features

Machine PAL PAL PAL PAL PAL PAL PAL/DEPAL PAL PAL/DEPAL PAL PAL PAL PAL/DEPAL ROBOT ROBOT Machine

Low speed Low speed

Medium speed Medium speed

High speed High speed

Loading HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH/LOW

LOW/ HIGH

LOW/ HIGH

LOW/ HIGH

LOW/ HIGH

LOW/ HIGH

HIGH/LOW LOW Loading

Magnetic head a a a a a a a Magnetic head



Layers/min. 2/2,5 3/3,5 7 5 4 5 4,5/5 3,5 2,5/3 3,5 2 3 2,5/3 5,5 ÷ 6 5,5 ÷ 6 Layers/min.

Products

Cans and boxes Cans and boxes

Unstable cans Unstable cans

Reduced height cans

Reduced height cans

Aerosol cans Aerosol cans

Full cans Full cans

Aluminium cans

Aluminium cans


L A S E R G U I D E V E H I C L E S

ShuttleLGV

Laser guide vehicles work with a laser system which rotates 360° and detects the position of mirrors installed in the operational area. Thanks to their triangular set-up, the mirrors can always fix their position and therefore the distance to cover.

Safety system able to detect the obstacles and

their distance.


Side safety system made by Bumper. The contact between the inside sensors stops the shuttle immediately.

Display for manual function.

Motor functions control for manual operations.

High return of investment

Using laser guided vehicles instead of standard forklifts, ensures a very short-term return of investment. Companies which work on different work-shifts should seriously consider this kind of technology in order to save more money in a short-term period.

Store integration and management

Laser guided vehicles allow good store management as, owing to particular algorithms, they are able to position their load in accessible ways according to specific batches and codes.

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R O B O T


This kind of pallet transport is suitable for plants where there are multiple loading or unloading stations for empty or loaded pallets. The shuttle can support from 1 to 3 pallet positions, side by side or overlapped according to the number of pallets/hour to

palletise or depalletise. An upper pressing device for full pallet is installed on board in case there are pallets with unstable loads to handle (for example aerosol cans) avoiding the fall during translation.

Highlight

Shuttles on rails allow a step forward towards the automation of production line to be mades. For handling empty or loaded pallets, these machines can replace traditional forklifts for most movements.

S H U T T L E O N R A I L S

Automatic shuttle for pallet handling on railsMT 558


The handling area can be delimited to operators by safety guards or, otherwise, can be installed in a free area and equip-ped with front, side and back PLS laser protections which gua-rantee a high reliability and are made according to safety Euro-pean CE Directives in force. The rails are preferably installed in

the ground (buried), in order to avoid any raised obstacle and allow the passage of any vehicle or equipment often used by operators inside an establishment, for example forklifts or tran-spallets.


Motorized chain conveyors Conveyors for pallets equipped with 2-3-5 motorized chains, 1” or ¾ “. This kind of conveyor allows handling of the pallets flat on chains, assuring the best steadiness and completely avoiding the packages to fall from the pallet during translation, even the most unstable.

Motorized roller conveyors for palletsThis kind of conveyor is used the most for pallet handling. With its modular rollers, this conveyor gets different handling so-lutions for empty or full pallets. The rollers size is calculated according to the size and weight of pallet to be moved.

90° pallet deviating conveyorsThis kind of conveyor allows a 90° pallet deviation, for both empty and full pallets, by a transfer section made with rollers and chains. The chain or roller lifting device is composed of an electro-pneumatic or electro-mechanical system. The dimension of the deviator is decided according to the type, height and the size of pallet, in order to optimize the operation and make it safe and correct.

90°, 180°, 270° rotating tableIt is composed of a motorized roller conveyor installed on board of a rotating table which allows a 90°, 180°, 270° pallet transfer.

Highlight

Pallet transfer for full or empty packages requires the greatest attention in order to guarantee the maximum steadiness and face the requirements of any kind of layout.

M O T O R I Z E D R O L L E R O R C H A I N C O N V E Y O R S F O R T H E C A N - M A K I N G I N D U S T R Y

Pallets conveyors


Thanks to modular roller conveyors, there are different pallet handling solutions for both empty and full pallets.


Everybody talks about safety, but only a few people know the Social Accountabili-ty, that is to say directive SA 8000.Mectra was one of the first to take care of the process based on ethical principles of American society SAI, ethics begins when we start a process according to UNI EN 12100 (part 1 and 2), realizing also the technical issues of the production line of the customer. We plan “security”; it is not considered a chance to speculate or just an idiom but it is integral part of our projects, it is source of our innovative ide-as. We do not think that a safe machine is less efficient than a machine free from sa-fety systems. We think that it is necessary

for all companies (also end users) which want to be abreast with the times and avoid the effects caused by an incident, to go on building companies and machines in this way. We refer to European Direc-tives application concerning safety and workers health protection.

Directive n. 654, «Work places», establishes thebasic safety and health prescriptions for workplaces. It is applied in every public and private workplace (except for public tran-sport, installation sites, mining industry, fishing boats, fields and lands of the farm outside of the constructed area).

Safety producers

Protections, alarms, sensors are equipment which some manufacturers may consider unnecessary as they increase the cost of a line. We think that assuring the operators’ safety is a priority, as this is the best guarantee for companies to face no troubles and no legal risks.

C O M P A N I E S S E R V I C E T E C H N O L O G I E S

Safety at work, manufacturer’s and buyer’s risks and responsibility


Directive n. 655, «Use of equipment», lays down the basic safety and health requirements for the use of work equipment; its application is wide: every work where machines, devices, tools and plants are used.

Directive n. 656, «Use of individual safety protections», controls the basic safety and health prescriptions for the use, by workers, of individual safety protections during their work, every time they are not in a position to avoid the risks of their activity by the use of the community safety protections. C O N T I N U E

Location of areas with higher potential risk

We do a careful analysis of potentially dangerous areas for operators, in order to apply all safety rules.

Mectra is able to supply regulation conformity documentation to areas outside of Europe but still complying with local legal requirements ones (Australian, American, and so on).

On the left, is an example of conformity to Australian Standards.


It is clear that it becomes necessary to apply to a trustworthy partner in such a wide legislative scene, even when applying to safety directives. Some example of compulsory regulations referred to the Technical Direc-tives and valid in the European Community:

Anti-drop systems during lifting. EN 415-4

Safe distances assessment. EN 12100-1 and EN

12100-2

Reaction time assessment of the systems detecting a man towards a danger. EN 999

Risk assessment. EN 14121-1

Safe distances in order to avoid reaching dangerous areas with upper limbs. EN ISO 13857

Emergency stop. EN ISO 13850

Safe distances in order to avoid reaching dangerous areas with lower limbs. EN ISO 13857

Basic distances in order to avoid crushing parts of the body. EN 349

Prevent unexpected start-up. EN 1037

Interaction between men and warning / control devices. EN 894-1

General prescriptions for the project and construction of protections (steady and movable). EN 953

Product technical documentation – Use instructions – Index and exposure of contents. EN 10893

Machines electrical equipments. EN 60204-1

The list is just a part of the technical directives applied to our machines, as, in addition to A type, we also em-brace C type, indicating, for each working group, the right regulation.A great job in order to guarantee in time safe machines with regard to any aspect; the technical file, the risk assessment, the manual of use, the safety calculation, the conformity evaluation, the conductivity tests, the electrical tests, the speed and men reaction assessment as regards a danger, have been expressed and clas-sified inside a file which is the technical order of the plant. In the same file there are all improvements and verifications made during installation and commissioning, which were done in the workshop. As a matter of fact, the safety and working test bench is made at our premises, facing not only the end user requirement, but also the technical and legislative provisions coming from European Directives and from the laws of the State where the plant is installed.

We always learnt from our policy and our history to supply efficient running and safe machines.

C O M P A N I E S S E R V I C E T E C H N O L O G I E S

Safety at work, manufacturer’s and buyer’s risks and responsibility f o l l o w s

All rights reserved. Technical details, features, setting-up and regulation references can be changed without prior notice obbligation. Therefore, Mectra S.p.A. declines all responsibility for any injury arising from lack of or incorrect information here reported.

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w w w . m e c t r a . i t

Mectra S.p.A.Via Luigi Galvani,9 | 42027 Montecchio Emilia (RE) Italy

Ph. +39 0522 868411 | Fax +39 0522 864536e-mail: [email protected] | VAT number and tax code 01231410356

Register of companies RE 15501 | Capital stock € 300.000,00 fully paid-in

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