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Personal Care CPG to Carton at 600 ppm with Robots, Linear Servo Track

Edgewell Personal Care's new IF monoblock system, built by OEM Cama, uses four robots to pick and place product, then close cartons carried on B&R Acopostrak linear track systems.

Transcript
Transcript

Hi, I'm Billy Goodman, Managing Director for Common North America. I'm very proud to introduce our latest development here at PacExpo 2024 in Chicago, which is a machine, we call it an IF monoblock system, for our customer Edgewell.

This system takes up to 600 products per minute and loads into a variety pack. We also actually have this from two lanes, so basically you've got two lanes of products coming in, And they are now sequenced into a racetrack system, where they're picked and placed into boxes. Those boxes can range in size from 8 count all the way up to 48 count. We also make a 3 lane system, which can run up to 1, 800 products a minute. Once again, 600 products per lane. Some of the features of this machine that we're trying to highlight today, and which are really first introduced at this show, is number one, the The consolidated robotic system. We actually have four robots in here, all working together. One robot is forming the boxes.

One robot is closing the boxes. And the two robots closest to this view are actually picking and placing the products into the boxes. Another big feature of this, this is the first time we're introducing our BNR track system that we introduced, uh, really for our high speed applications. And the real, the advantage of this system is really in the ability to change pitch throughout the machine.

With a magnetic system like this, we can be at a wider pitch that you'll see further on downstream where we're forming the boxes. We tighten the pitch to load so we can have multiple boxes at a time in the loading station. And then we open the pitch up again on the closing side of the machine. We're going to look at two additional stations on the machine a little bit closer up.

Right over here, we're doing the forming. So we've got in here a triple magazine. So we've got three magazines holding case blanks and a robot taking the blanks, applying glue and forming and forming the cartons and placing them into the magnetic carrier. After the cartons are loaded, they come all the way around the track and then the station over here, we're doing the closing.

And once again, we're using the same robot. With a different apparatus to do the closing of the carton. My name is Vladimir Martino. I'm Global Packaging Manager for B& R. And we are in a KAMA machine, a top loading machine, where we can see the ACOPOS track in action. So, we are quite proud to partner up with KAMA on such a really nice machine.

One of the challenges in this machine, challenge number one, was The machine has to be able to serve three different lines upstream with the same speed but different cadence. So one of the main challenge for the customer is how to reduce, you know, all the buffering that normally with the traditional system you need to combine three different, three different, cadence line.

The ACOPOS track allows to Compensate these different cadence due to the fact you can control independently individually each single shuttle and this is the challenge number one.

Challenge number two is how to reduce the change over time because you know the shuttle can be adapted. The pitch can be adapted depending on the size and the dimension of each single cartoon box.

Challenge number three is a performance. I mean one of the main target Toti machine is reach higher performance, and this is mainly due to the fact, as you see, the machine is an intermittent machine. So you need a system that is able to accelerate the accelerate and go at the maximum speed. One of the key feature of Pose track that it can run up to four meter per second with 5G of acceleration, deceleration, and to reach this solution.

At the beginning, it was not easy. You know, when you have a complete new system and to get the maximum of the value out of the system, you have to think a little bit out of out of the box. So what we have done together with the camera technician, we use simulation as a tool for the co creation. So we designed different kind of option to read and to check what what is what the best layout is for for them.

And then at the end we arrive at this fine solution. What was really good that, from the simulation to having the ACOPOS track cycle in place, it took just one day. So they just downloaded the software of the simulation they run the ACOPOS track, and it was perfectly matching what we expected in the simulation.

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