Cold End for hollow glass manufacturing plant in Saudi Arabia
In autumn 2015 a new melting tank for the production of bottles and container glass at The National Company for Glass Industries (ZOUJAJ) in Riyadh / Saudi Arabia was commissioned into operation. The complete cold end, including bottle conveyor systems, palletizers, shrink-wrapping system, pallet conveyor system and a networked control software, was supplied by the partner of many years and leading international equipment manufacturer, MSK.
Holistic solution
Over several years the machinery manufacturer MSK developed an equipment concept for the cold end of the so-called "Expansion Project" at National Glass Zoujaj, in close collaboration with the project managers of the Saudi Arabian hollow glass manufacturer. “The National Company for Glass Industries “ZOUJAJ”, a Saudi Joint Stock Company, in glass bottle manufacturing business, carried out its expansion project that has started its commercial production recently”, explains Yousef Al-Salman, General Manager at National Company for Glass Industries (ZOUJAJ). “For the supply of machinery, erection, and commissioning of complete cold end solutions (from bottle conveyor system up to pallet conveyor system), ZOUJAJ approved MSK for the job on key-turn basis, in view of their credentials, state of the art technology, expertise in the field, and prompt after-sales maintenance service and cooperation. During these few months after the start-up of the plant, the machinery installed and commissioned by MSK has been functioning well according to our satisfaction”, Yousef Al-Salman adds. Already in 2006, MSK supplied two new fully automated palletizers with automatic tray-makers for the existing tank. The glass manufacturer was really impressed by the holistic concept for the solution now supplied for the second tank, which extends over two levels: All the machinery supplied by MSK for the cold end, from the glass lehr right to the pallet packaging system, was supplied from one source and as turnkey installation. This made it possible to achieve without numerous component interfaces as potential sources of errors, and it was possible to network the entire system with standardized control software.
Bottle conveyor system in premium quality
From the glass lehr onwards the MSK bottle conveyor systems take control of the production on two lines and ensure a smooth flow of bottles through the inspection machines, right to the palletizing station. Since production extends across two levels, the bottles are conveyed by MSK bottle lowerators from the second floor to the first floor, where the palletizers and shrink-wrapping system are installed. MSK bottle conveyor systems are made of stainless steel and premium components for a special long service life, and are controlled by the MSK EMSY software.
Centralized pallet preparation
The MSK palletizing system is supplied with empty pallets from a centralized dressing line. In addition to the placement of a base film sheet, the empty pallets are also fitted there with cardboard or plastic base sheets. An MSK shuttle car transports the stack of finished empty pallets on to the two newly installed palletizers.
Clear savings due to universal palletizing
The use of the MSK Duotech rotating-arm palletizing system, combined with the MSK Unitech universal head, offers great benefits. Compared to a gripper-tube system, the universal solution allows quick and easy job changes. Moreover, the consumption of air is considerably reduced and there is no need for the subsequent purchase of spare parts when wear occurs on gripper tubes. The new palletizers are equipped with MSK tray-makers too.
Flexible pallet packaging for the global market
The finished pallets are packaged with a robust protective UV film by an MSK Multitech shrink-hood wrapping machine. The MSK undershrink system fastens the film far under the pallet base, so it ensures high load stability at reduced film thickness. The economical and reliable MSK Econotech secure shrink system heats the film gently with hot air, increasing the fatigue strength of the film this way, even in cases of longer storage outdoors.
For the Saudi Arabian region, the MSK Multitech packaging system is an ideal packaging solution that is being increasingly put to use by glass manufacturers. The machine can be supplied as multi-format system, so it can be equipped with up to four different film formats. "This makes it possible to flexibly package both European pallets as well as overseas pallets, for example – an important requirement for manufacturers that are oriented to the world market," explains Uwe Jonkmanns, Sales and Marketing Director at MSK.
Automated pallet transport thanks to shuttle car logistics
An MSK shuttle car with two pallet places connects together the separate stationary conveyer lines. When requested, the yet unpackaged glass pallets are conveyed from all the palletizing lines to the shrink-wrapping system. Here the shuttle car supplies both the newly installed machines as well as the palletizers that were previously in place to handle production from the first tank. The shuttle car even serves the dressing line that is integrated in the overall system for the preparation of empty pallets. In total, the mobile pallet conveyor is designed for a capacity of up to 60 pallets per hour. It replaces forklift traffic between the individual lines, so it provides a quiet, reliable and automated flow of materials.
Networked information technology with MSK EMSY 5
At National Glass the entire cold end is controlled by MSK with the special MSK EMSY software, which was specifically developed for MSK equipment. The intuitive visualization software with its 3D animations makes operation easier and shortens the time necessary for familiarization. Once a parameter has been entered, it can be automatically transferred to other machines. It is possible to trace the products throughout the entire logistics system with the software, and also to control the overall system. One special feature is that the palletizers, as well as the bottle conveyor installed in the same hall, can both be operated from one and the same EMSY terminal, which reduces both costs as well as space requirements for the hardware.
Cooperation as partners
ZOUJAJ and MSK are already working together on the next project: as a result of the successful work together, in 2016 MSK will again be supplying new cold-end equipment with bottle conveyor and palletizing systems for the first tank.
