SetLine is designed to pack various shapes and sizes of single cups,
cup sets and bottles into trays or cases, with the ability to sleeve
the primary packages into multipacks. Quick-change format parts are
provided for the different cup types and sizes.
The modular design can stand alone or be directly integrated with a filling machine and tray erector.
The end result is a ballet of continuous motions at rates up to 30,000
bottles or 43,000 cups per hour, with a range of pack patterns and
sleeve configurations possible.
In the interpack demonstration, SetLine created 4-flavor rainbow packs
from single flavor packs diverted from their respective fillers at up
to 500 trays per hour.
How the rainbow packing process works
Product in trays or cases is fed onto 4 gravity roller conveyors which
provide an infeed as well as a buffer. A driven roller section
separates the trays or cases. A robot places the trays into the
carrier chain and indexes them into the re-pack position.
Product is removed from each of the 4 trays by servo-driven de-packing
grippers on the pick & place robot and automatically spaced to the
corresponding pitch of the target trays. The assorted cups are
deposited onto a positioning plate in the correct pack pattern.
The robot is equally capable of packing assorted trays from
single-product trays or packing single-products trays from mixed trays.
But first, sleeving is performed by a robot that takes sleeves from
magazines and places them in a transport carriage. At the sleeving
station, the cups are removed from the gripper plate and placed into
the U-shaped sleeves in the transport carriage.
In parallel, empty trays are fed to the SetLine from a case erector. A
gating system cycles the trays to the loading station where a third
robot packs the sleeved sets.
A top flap closing unit is swivel mounted to clear the transport
carriages. A transfer gripper uses actuators to ensure that the
sleeved sets are accurately spaced prior to being tray or case packed.