Two Pearson CE50-G Case Erectors use top and bottom vacuum and a servo-driven set-up arm to erect knockdown RSCs (regular slotted containers). The minor flaps are closed, hot melt glue is applied, and a compression ram presses into the case to close the major flaps against a back-up plate. The erected cases are rotated 90 degrees at the discharge to be turned upright and conveyed away.
An existing third-party bliss former is integrated to form display bliss cases for bulk product runs. A bypass mode enables open bliss boxes to travel through the sealer along the same path as the RSCs, keeping conveying and overall footprint to a minimum.
The continuous motion sidebelt conveyors transport the cases/boxes to dual packing stations. One timing screw diverts the products into two lanes, while a second timing screw groups them into the appropriate pack pattern. Line tracking determines the product location.
Four FANUC LRMate 200iD/7L robots use a custom end-of-arm gripper tool to pick and place products into the cases in arrangements of 4, 6 and 8-packs. Auto tool change reduces changeover time between product sizes and pack patterns.
Filled cases are identified with a barcode label, applied by a set of integrated print and apply labelers. A pair of third-party checkweighers with reject stations ensure cases are complete.
Two Pearson CS40-67G Case Sealers fold the RSC minor flaps, then apply hot melt glue and fold the major flaps. Cases are conveyed beneath compression rollers for sealing.
In the palletizing cell, a pallet is released from the dispenser and conveyed to the load build station. The FANUC M-410iC/185 palletizing robot picks a slip-sheet from the automatic dispenser as it receives RSCs from two lanes. As an alternative, bliss boxes are received in a single lane and also palletized in the cell. The cases/boxes are turned and accumulated for picking. RSCs are picked with a custom vacuum end-of-arm tool, while bliss boxes are picked with a custom fork tool and layered according to the selected pack pattern. Automatic tool change simplifies the transition between different case/box styles.
Once a pallet stack is complete and discharged from the cell, it is transferred to an automatic stretchwrapper where the pallet stack is wrapped. Finally, a takeaway conveyor transports the pallet to a third-party label printer which tags the pallet stack for shipping, and the sequence repeats.