Platform for the food and beverage industry
In order to ensure quality, automation is increasingly being looked at. Also at Avamoplast. A camera system now monitors the perfect positioning of the label for IML packaging. But how do you integrate it perfectly into your process? KoMotion designed and installed a cobot solution that can perfectly follow the brisk pace of the packaging line. And the operation? Yes, it's child's play.
One material. Endless possibilities. 100% recyclable. That's what sets Avamoplast's plastic packaging apart on the market. It was the experience with and passion for that made André Van Moeseke see salvation in the possibilities of plastic for food packaging. Meanwhile, with Sylvie and John, the second generation is at the helm, with the same dedication and focus on quality. "Our company has plastic in its genes," opens John van Moeseke. "Just because it is such a valuable material for packaging food. The negative reputation it carries is misplaced here. After all, by working with monoplastic we keep the environmental impact extremely limited. Our packaging is easily sortable and recyclable." On an annual basis, Avamoplast in Lokeren produces 150 million pieces for its customers. 90% of these are destined for the food industry. From small lids to large bins, trays or trays.
The production site offers two techniques under one roof: thermoforming and injection molding. "That way we can really focus on what can best serve the customer. In terms of technology, material but also logistics and marketing. A total solution that goes beyond standard materials. We look at how we can optimally produce his packaging to create added value." Customization, then, yet Avamoplast is betting on extensive automation. "By standardizing. If we can ingrain a fixed way of working in all our processes, those investments will pay for themselves in the long run. But we are also looking at ways to support our 35 or so employees as well as possible in their daily activities with technology," says Van Moeseke.
A recent project involved the production method IML, in mold labeling. Van Moeseke: "In the injection mold, the label fuses with the plastic packaging. A process that requires attention to ensure that the label is perfectly positioned." Avamoplast went as far as possible to further regulate the IML process, but a manual check by the packers still remained necessary. "This still presented logistical challenges and longer lead times with large runs. The idea was therefore to integrate automatic quality control using camera technology for the packing process." The feed from machine to camera and from camera to packing table would have been realized in the past via a classic robot. "However, the space was lacking on the shop floor and, in addition, we wanted a flexible system that could get away with multiple packages."
Van Moeseke was particularly charmed by the possibilities of cobot technology. A little Internet search later, it came to KoMotion. "The work they had put into preparing the project and the test setup was particularly thorough. Moreover, the team's enthusiasm was also contagious. That practical, hands-on mentality matched ours perfectly." KoMotion first designed a conveyor system to guide the IML packages past the camera piece by piece. Then it was up to the cobot to put them away with a compact footprint. "The challenges here was getting the jars the right distance apart to pick them up and then stacking them in the right place."
Check and check. In no time, the team at KoMotion had a design ready that could handle several packages at 32 pieces/minute and stack up to 45 jars high. In theory. Then it was a matter of fine-tuning the process and getting it ready for practice. "The containers coming out of the IML machine can still have heat and be statically charged. That makes it just a little less obvious to stack them perfectly stable," Van Moeseke knows. KoMotion tackled the problem hardware and software-wise. With an isolator for the robot, they were already able to neutralize part of the static charge. Through optimizations in the software, they got it further on point. They also left room for integrating another insulator to the cobot, if needed.
The result is an automatic quality system that more than does its job at Avamoplast and much improved flow and operation. "Actually, after three weeks we were very close to expectations. In fact, some packaging is already running 100% flawlessly. But the last percent requires time and experience. The camera therefore has machine learning on board." Van Moeseke is also particularly pleased with Komotion's solution. "The enthusiasm and the will to make the project succeed lead to a constructive approach. A solution was immediately proposed for every problem so that the project kept moving forward. This was also necessary, because this is a busy machine. We cannot afford much downtime. So KoMotion was given little implementation time but, thanks to thorough preparation, succeeded with flying colors. And the staff is also satisfied. Everything is structured so logically that they know what to do without much training. Cobot technology certainly tastes like more."
