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?®Everyday hero?? stretches savings at The Coleman Co.

A two-station machine stretch wraps a bundle of boxed coolers while a second is readied for the other station to save more than 37% in time and labor.

After delivering a load of boxed coolers onto the left side of the shuttle table, a clamp truck driver backs away and pulls a la
After delivering a load of boxed coolers onto the left side of the shuttle table, a clamp truck driver backs away and pulls a la

On its Web site, The Coleman Co. lists many of its outdoor camping and leisure-time products under the heading ¡°everyday heroes.¡± That moniker is equally apropos for a stretch wrapping system the company added last year to bundle groups of boxed coolers made and stored at Coleman¡¯s plant in New Braunfels, TX. The wrapped bundles are used only for internal purposes.

These bundles, or cubes, are stretch-wrapped on an automated system from Orion Packaging Systems (Collierville, TN). Orion designates the system as its MPA-66 DST, a modified platform automatic dual-shuttle table that it developed for Coleman after meeting at the New Braunfels facility with Coleman¡¯s manufacturing engineer Raymond Wehmeyer and representatives from distributor Pack-Mark (San Antonio, TX).

Before adding the Orion unit, the New Braunfels plant used another vendor¡¯s dual-station stretch wrapper, which it still employs primarily for additional capacity.

¡°We¡¯ve had good performance out of that machine, but it used a much more manual process than we now have with the new wrapper,¡± notes Wehmeyer. The former process required a worker to first place the load in a circle painted on the floor. Then the worker would step off the clamp truck, swing the wrapper¡¯s arm to the load, grab the tail of film from the carriage, and tuck it into a corner of one of the boxes on the load before pushing a button on the machine to initiate the wrapping cycle.

Now, Wehmeyer says, the clamp-truck driver positions the load on one of the two stations on the moving platform, backs up, and pulls a lanyard switch to automatically move the load into position for stretch wrapping, without having to leave his truck. That¡¯s reduced time and labor costs by 37%, according to Wehmeyer. A lanyard switch is positioned at both stations.

Unusual shuttle system

What makes the new system unique is not the overhead tower wrapper itself, which ascends and descends as it orbits the skid, but the low-profile shuttle table. The table, which had to fit into a tight space in the plant¡¯s warehouse, includes a steel bottom frame structure that is bolted to the floor. The frame includes a track with rails that allow the top steel table to slide left or right on wheels. Electricity powers the system. Workers can load and unload boxed coolers from both stations.

The moving platform measures around 20¡¯ long and accepts bundles from either of two positions. Once a group of boxes is placed onto the table from the left side, the clamp-truck operator backs away from the table and pulls a chain that¡¯s attached to a switch mounted overhead. Pulling the switch triggers the platform to move by sending a signal to an Allen-Bradley MicroLogix¢â PLC, supplied by Rockwell Automation (Milwaukee, WI). The PLC then activates the table to move that load to the wrapper. The automatic rotary tower wrapper applies 80-ga linear low-density polyethylene stretch film from AEP Industries (South Hackensack, NJ).

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