Complete cold end from one source for new glass plant in Turkey
For the new Bastürk Cam glass plant in Malatya / Turkey, MSK has delivered the complete cold end including controls and assembly from one source. Production started at the beginning of January 2018. The cold end includes the connection of the lehr with three bottle conveyor lines, palletizers, shrink wrapping system, and pallet conveyors and has already been designed for extension by an additional furnace.
Full-service supplier with experience
At GLASSTEC 2016, the Turkish manufacturer Bastürk Cam placed an order with MSK for delivery of the complete cold end for its new glass production plant in Malatya. The decades of experience and leading know-how of the full-service cold end provider MSK was one of the decisive factors for the glass production newcomer. The cold end was designed for an existing building structure and started up less than a year later. MSK ensured the best-possible communication with the project owners at Bastürk Cam with a Turkish-speaking project management team at MSK and Turkish-speaking on-site assembly team in Turkey. MSK delivered all the equipment for the cold end starting from the lehr all the way to the pallet packaging from one source and as a turnkey installation. This helped rule out several component interfaces as error sources and network the entire system with a uniform control software.
One source from lehr to packaging
Production at Bastürk Cam started on schedule in January 2018 with the start-up of the first lehr. The produced bottles and jars are transported on three bottle conveyor lines through the inspection area to the palletizers. MSK bottle conveyor systems are made in-house from stainless steel and premium components to ensure a long life and, like all MSK machines, are controlled uniformly by the same MSK software EMSY.
The three installed palletizers MSK Triotech are equipped with the universal palletizing head MSK Unitech. This allows for the flexible production of the various glass products in Malatya with the same palletizing head without downtimes for job changes. The palletizing stations are supplied by a central dressing line with two pallet formats. After palletizing, pallet conveyors and a mobile MSK pallet shuttle car transport the glass pallets fully automatically to the shrink-wrapping line MSK Multitech, where they are film-wrapped and thus protected on all 6 sides for storage and transportation.
Savings with universal palletizer
The swivel-arm palletizing system MSK Triotech in combination with the universal head MSK Unitech as is used at Bastürk Cam provides a great benefit since all products can be processed by one and the same palletizing head. Compared to a gripper tube system, the universal solution thus saves a significant amount of time for job changes. In addition, the air consumption is significantly reduced and there is no need to buy replacements for the wear parts of the gripper tubes. The palletizers at Bastürk Cam process up to 3 layers per minute and are also equipped with three MSK traymakers, a central intermediate sheet inserter and cover sheet/tray inserter, as well as a wood frame inserter. The central dressing line pre-assembles a bottom film sheet for the empty pallets, which in combination with the film hood later forms an all-round sealed packaging. MSK Triotech palletizers stand out due to their space-saving construction and low wear, since the palletizing column stands firmly on the floor and only the arm swings around the column.
Flexible pallet packaging
With the MSK Multitech shrink-wrapping system, the cold end in Malatya has a compact, high-performance, and flexible solution. The system is equipped with two film formats and makes it possible to package up to 60 pallets per hour. The compact design with lowerable machine head at the working level and maintenance-free time belt technology allows for simple and quick maintenance and ensures very low energy consumption. "The MSK Multitech pulls the film hoods over the pallet loads without touching them. This is a very safe packaging solution for sensitive glass products and also makes it technically possible to use thinner films, which has a positive effect on packaging unit costs", explains Uwe Jonkmanns, Director Sales and Marketing at MSK. The film is shrunk using an MSK safety shrink frame. The special warm air mixing process heats the film in a targeted and gentle manner, allowing it to retain its tensile strength and durability. MSK shrink frames work with heat recovery, significantly increasing energy efficiency.
Automated flow of materials
The MSK shuttle car has the central task of fully automatically connecting all production, palletizing, shrink-wrap, and empty pallet lines without using a forklift. In terms of capacity, it is already designed to cover the addition of an additional furnace, which is planned for 2019. When required, the still unpackaged glass pallets are transported from all palletizing lines to the shrink-wrapping line. The shuttle car also covers the central dressing line for the preparation of empty pallets. Overall, the mobile pallet conveyor is designed for an output of up to 60 pallets per hour and thus ensures a quiet, safe, and automated flow of materials.
Uniform and networked control with MSK EMSY 5.4
MSK controls the entire cold end at Bastürk Cam with the MSK EMSY software specially designed for MSK systems. The intuitive visualization software, equipped with 3D animations, is easy to operate and shortens the training time. Any parameters that have been entered once can be transferred to other machines automatically. The software allows to trace the products through the entire logistics system as well as to control the overall equipment.
