Turnkey end-of-line packaging system for bagged goods
KLK EMMERICH GmbH, part of the international concern Kuala Lumpur Kepong Berhad, has commissioned a new end-of-line packaging system for bagged goods. The system consists of a robotic palletizer, a stretch-hooder for securing loads, and a pallet conveyor system as turnkey solution from MSK.
Palletizing, packaging and conveying all from a single source
The request for a flexible and efficient system for packing palletized bagged goods from the chemical manufacturer from Emmerich am Rhein resulted in an impressive overall solution that went far beyond the scope originally envisaged. "The previous KLK packaging system was over 40 years old and also from the manufacturer MSK. The catalog of requirements for a new packaging solution included the maximum system throughput, stable pallet load configurations and packing patterns. We also opted for a stretch-hooder,” explains Jörg Bujar, Product Finishing & Logistics Team Lead / Hazardous Goods Officer at KLK Emmerich GmbH. “The robotic palletizer had to be able to insert a cardboard sheet between the wooden pallets and the bags, which prevents bag defects. In addition, each container is checked for foreign objects using a metal scan. Together, we configured the entire system in such a way that customer complaints would be avoided and the system would be fit for KLK Emmerich GmbH's future path into the food/feed/pharma sectors." It turned out that the system manufacturer MSK was able to supply all the necessary modernization and automation requirements from a single source, with connection to the existing bag filling line. A tailor-made concept for the KLK plant in Emmerich with a bag conveyor including scales, labeler and metal detector, as well as a modern palletizing cell with flexible and multifunctional robot technology, a sustainable packaging system for securing the pallet loads with a stretch hood and automatic pallet transport to the warehouse now ensures a completely automated, efficient end-of-line packaging concept. The MSK EMSY overall control concept in particular ensures smooth communication between all areas of the system and a material flow without interface problems. "The new system is not just a replacement investment. The entire system will allow us to ensure even better quality compliance in our deliveries to customers and initiate future steps with higher quality requirements," explains Jörg Bujar.
Multifunctional robot cell
The MSK palletizing cell installed in Emmerich is a multi-talent that performs many tasks simultaneously in a very small space. The bag palletizer gently and securely takes the 25 kg bags, supplied by the MSK bag conveyor, and stacks them flexibly on the carrier pallets according to the specified packing patterns. Empty pallets are supplied automatically via a stationary empty pallet magazine. The robot also performs tasks such as the placement of bottom sheets from a tray magazine and the ejection of products when a defect is detected during the quality check. Information about this is obtained by the controls over the network via the MSK EMSY software, which also integrates the scales, labeler, and metal detector to check each individual bag.
Compared to the previously installed layer palletizer, the new robotic palletizing solution is considerably more flexible, takes up less space and is more precise in layer formation. It is also particularly low-wear and therefore less susceptible to service and maintenance. Because they are manufactured in MSK’s own factory, spare parts are available for a long time. With the integration of the palletizing cell in the overall system, KLK profits from a homogenous documentation, software and spare parts architecture, including service for the entire system, without any potential caveats from third-party companies. "The high availability of the system, good service and maintenance experience and the price-performance ratio convinced us to buy an MSK system," reports Jörg Bujar.
Savings in load securing process
During the course of the project, extensive packaging tests were carried out at the MSK customer test facility in Kleve using KLK's original products in order to find the most sustainable and efficient packaging solution for KLK. With the installation of the state-of-the-art MSK Tensiontech stretch-hooder, KLK opted for the optimum packaging solution for bagged goods. The machine is equipped with two film formats, and with precisely tailored stretch hoods it ensures reliable protection against weather and good transport safety. With the MSK stretch process the film is stretched lengthwise and crosswise in any coordinates, which enables packaging with the thinnest of films. By placing the film around the top board of the pallet in a controlled way, the pallet feet remain free of film, so the pallets are easier to handle by forklift trucks. In contrast to a spiral stretching solution, the product, brand label and barcodes are clearly visible under the film, as the film is wrapped around the load in just one layer. The closed hood also enhances theft protection during outdoor storage.
Because of its compact design, the space and energy requirements of MSK’s stretch-hood solution are low. Maintenance requirements have been reduced using maintenance-free timing belt technology instead of hydraulics, and a machine head that can be lowered for maintenance tasks.
Uniform control of the entire system
In conjunction with the fully automatic palletizing and packaging system, the installed MSK conveying system works as an integrated transport and material flow system right into the warehouse and was also individually designed for the conditions in Emmerich. MSK conveying technology is produced entirely in-house and is known for its robust materials, high-quality powder coating and very long service life, even under the abrasive conditions of a chemical production plant.
As palletizing, packaging and conveying all come from a single source, KLK profits from a uniform and more economical overall control system. Networked communications and the adoption of parameters with the MSK EMSY software ensures easy operation without interface problems, and a central service interface. The complete system is visualized graphically in 3D. Even manual functions are displayed as animated 3D graphics. Error messages with picture support allow quick and easy troubleshooting. Using the integrated recipe manager, changes can be easily made to recipe, product or packing pattern, without the need for programming skills. The EMSY software also supplies consumption statistics, allows remote maintenance, backs up data automatically, and much more.
Regarding MSK’s technical implementation and project management, Jörg Bujar is positively impressed: “Working together went very smoothly at all times, and the level of transparency in discussions and problem solving was great. The project was implemented within the exact time frame. In the end, the project was in scope, on time and on budget. That's how a project has to be implemented.”
MSK – Partner of industry for palletizing, conveying, packaging and unpacking systems
For nearly 50 years, the MSK Covertech Group has been one of the leading manufacturers of palletizing, conveying, packaging and unpacking machines to automate the entire pallet handling process from goods receipt to truck loading or to the finished goods warehouse. Today, it has sold over 6,500 systems and has around 600 employees at sites in Germany, France, Hungary, the USA and China. Well-known manufacturers in the most diverse sectors are among its customer base. MSK develops and produces conveying technology and packaging systems with a high level of vertical manufacturing and even controls its systems with its own software.
