Case History FB Automazione Srl (for DIFARCO)
PRODUCT SECTOR: Study, design and consultancy for the manufacture of packaging systems and end of line equipment.
FB Automazione Srl, a company specialising in the study, design, consultancy and manufacture of box conveying systems, packaging lines and size detectors, asked us to manufacture, for one of its customers (which was operating in the logistic sector) two automatic self-dimensioning taping machines capable of closing and taping American corrugated board boxes with self-adhesive tape, as well as to stitch them with two or more staples, both on the top and on the bottom, without touching their content. Then, through suitable inputs from the line, these machines should have modified the working cycle, by cutting out the following functions:
– taping and stitching;
We were told later that the boxes used by the customer were in part recycled and in part new, and that they were not full, because their content often did not reach the full height level. They were used for sportswear and sports shoes.
The following data were submitted to us:
– Width: min. 250mm; max. 450mm
– Length: min. 400mm; max. 800mm
– Height: min. 200mm; max. 450mm
– Capacity: 4-5 boxes/minute without staples 2-3 boxes/minutes with staples;
– H (roller plane): 800mm +-50mm
According to the information provided by the customer and the box samples made available, our technical dept. designed the installation – on PV145/B taping machines, with standard technical and functional characteristics of two Stanley units (Roll Air Boxer AR34) for stitching boxes with 35x19mm staples, using a 5,000 staple roll, before upper and lower taping. Suitable suction cups would have lifted the box flaps during stitching, since these second-hand boxes did not ensure the support required for stitching.
Based on the project, the machines should have:
– fed the full boxes to be shipped (from the conveying lines) step-by-step, providing that their size did not exceed the limits specified above and in random format order;
– dimensioned themselves (width, height and length) based on the format of the fed box;
– folded the four upper flaps and closed the box;
– inserted two or more staples into the side flaps of the boxes (according to the box length and up to a maximum of four staples): on the top, under the box and in the centre;
– positioned the adhesive tape on the top of and under the box, in order to seal it;) checked the proper insertion of staples, according to the box length;)
– checked the proper and complete application of adhesive tape strips;
The technical solutions adopted for these machine, some of which had been implemented in the past, for box stitching applications requiring this type of operation, as well as taping (supplied by Grundig, Electrolux Seleco, Electrolux Zanussi), made it possible to work also with recycled American boxes. i.e. open and emptied from their original content, delivered after long sea transport, stacked flat and then formed, filled and conveyed to the machines. Each machine basically consisted of:
1) a feeder-spacer unit for incoming boxes;
2) side, vertical and longitudinal dimensioning systems for the fed box;
3) a closing unit for the four flaps;
4) a pneumatic upper/lower stitcher (5,000 staple roll), with empty staple roll checking device;
5) a suction cup unit supporting the side flaps, with Venturi vacuum generator;
6) simple and reliable upper and lower taping units (adhesive tape), capable of applying adhesive tape with adjustable vertical, rear and back sections (approx. 55 to 75mm);
7) reel braking device for easier control of the adhesive tape unwinding, also when using 1320m reels;
8) pre-unwinders/geared motors for easier unwinding of self-adhesive tape reels;
9) toothed belts with side gripping device made of rubber, for box infeed;
10) control devices for staples and proper taping;
11) lower adhesive tape reel holder, outside the frame, for easier replacement of empty reels;
The machines were operated in February 2005, to the customer’s full satisfaction.