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Robotics at the heart of latest Cermex applications
11.03.2010

It has now been several years since Cermex initiated a breakthrough change by integrating polyarticulated robots into case loading and palletizing applications. More than just a trend these days, the use of robotics opens up new prospects in terms of productivity, flexibility and ergonomics.

In continuation of its modular « Ready to Pack » range launched 3 years ago, Cermex is integrating more and more robot modules into its case packing equipment.

Often integrated into palletizing operations, smooth and rapid polyarticulated robots are also well suited to loading operations. Proof lies in the numerous interesting applications installed recently by Cermex worldwide to handle all types of products of varying shapes and nature.

These applications demonstrate the importance of the design strategy favored by Cermex: by functional and industrial sub-assemblies.

Robots do it all

Cermex proposes a whole range of loading arms and solutions to meet its customers’ requirements.

The Strong Points of robot integration into Cermex case loading solutions:

• Handling of products which vary in nature, shape and geometry on the same machine, including flexible products (bags, doypacks, etc.) with optimum product protection (label, color printing, etc.).
• Reduction or elimination of mechanical parts for collating products, resulting in improved accessibility as well as quicker and easier size changeovers.
• Product collating and gripping optimized and secured prior to loading.
• Accurate movements and high speeds.
• Integration of a complete range of robots suited to all payloads and speed.
• Polyarticulated robots to fit into production sites where low ceilings are a major constraint.
• Compact unit which can integrate product collating, case forming, loading and gluing, and even palletization.
• Quick and frequent size changeovers. Certain size changeover adjustments can be carried out directly by the robot (change of product gripping tooling, setting of mechanical stops, etc.).
• Machine versatility, thanks to the intrinsic re-engineering possibilities of the robot concept.
  

Several recent applications:

• Loading of cartons or flowpacked aluminium trays on a wrap around case packer with dual robots:

The originality of this installation at Celtigel, key player in ready-made meals in France, resides in the integration of 2 6-axis robots for collating the products and loading them into trays with ledges. The gripping head at the end of the robot arm is specifically adapted to form the batch of products directly in the gripping tooling. This concept does away with the product collating section which is more mechanical, hence less flexible. In addition, rather than running the robot in accordance with the product infeed speed, the use of two loading arms halves the cycle speeds of each robot in order to optimize the installation’s long-term reliability.

• Mixed products in the same packaging:

Again for Celtigel, but for promotional campaigns, the objective was to form packaging collating several references of cartons of ready-made meals. The products are fed in on a total of 5 lanes maximum. The robot groups the products in its tooling, by positioning itself successively at the outfeed of each lane (1 lane = 1 product reference) to collate the number of products required. In addition, the use of the 6-axis robot does away with using a loading funnel; the introduction of products inside the case is carried out by the accuracy of the movement of the 6th axis (wrist).

• Multi-function and multi-packaging in the same unit:

Sold to a Spanish plant of a major group in home and personal care, the WB45 case packer integrates a 6-axis robot to carry out various functions with a unique tooling. The robot first grips the plastic thermoformed trays. The products (shoe polish) are fed in lying flat, lengthways on one lane. The 6-axis robot grips 2 products flat and by the rotation of the wrist, introduces the products into the buckets of the plastic tray. The robot then transfers the filled tray onto a cardboard blank (complete single-flute wrap around) which is pre-formed into a U shape. The products and blank are then transferred to the folding and gluing station.
2 types of packaging and 3 functions in the same compact unit.

• A robot unit for all end of line operations:

According to Cermex’s design team, product collation, case loading, labeling and palletization in a single, very compact robot unit is what seduced the French site of a world leader in personal and beauty care. After preparing layers of cosmetic cartons, a polyarticulated robot carries out the product loading to form 3 layers in an RSC. Once the case is filled and sealed, the robot picks it up with the same suction gripping head for the case to be labeled, controlled (with automatic rejection by the robot if the case or label are non-compliant) and palletized. The palletization is carried out on a single station, but the robot transfers the cases to a buffer zone to avoid stopping the machine during pallet changeover.

These 4 examples, taken from a long list, demonstrate the contribution of robotics in the final solution, while underlining the importance of the modular architecture design in end of line machines, for increased flexibility, ergonomics, cost reductions (TCO* approach) and versatility.

In parallel to the integration of robots manufactured externally, Cermex continues to design, manufacture and install its other case loading machines:

• AN range of numerical axis gantry packers
• Traditional mechanical E458/E460/E478 Pick and Place Packers.

With the widest range on the market, Cermex reinforces its position as leader in the study and manufacture of tailor-made solutions to guarantee the satisfaction of its customers.