From sheet plant to board plant

Published in the International Paper Board Industry, September Issue 2017

Intralogistics by MINDA combines production and converting

For more than 20 years, the companies ZERHUSEN Kartonagen and MINDA have been continuously cooperated in the field of intralogistics.  Whether infeed and discharge to and from different converting machines or the connection to the high-rack warehouse - the specialist for cardboard from Damme can always rely on customer-specific solutions from MINDA. 

With the investment into their own cardboard production Zerhusen Kartonagen made the step from a converter to a cardboard producer.  MINDA could convince with their concept for the discharge of the cardboard stacks from the corrugator, the transport into the new high-rack warehouse and into the new in-house storage as well as to the converting machines via a transport bridge.  The flexible solution is designed for goods with as well as without pallets, whereby special importance was attached to the transport of large-size products.

Discharge from the corrugator

The stacks leaving the corrugator are composed to corresponding blocks and optimized. After having turned the stacks, the optimized block is positioned in front of the pusher. The optimization in length direction, the accumulation, is realized by the same mechanics, only by means of adjustable software components.  The pusher laterally pushes the block onto the parallel section. A second block is positioned near the first one. The positioned blocks are now centered and parallel and thus ready for simultaneous transport. The transfer car takes over both blocks at the same time, optimally using its capacity.  This process supports a better usage of space of the following intermediate storage and leads to an efficient transport to the converting machines.

LIFO intermediate storage to buffer goods and optimize residual stacks

The discharge lines convey the goods to the central pallet loading station.  Here they are palletized; after that the stacks are measured and weighed.  Thus, all criteria for stacking in the new high-rack warehouse are fulfilled.  Large-size products are directly discharged and prepared for dispatch. A second line lifts sheet plant delivery, which is to be immediately converted at the machines or stored in the in-house storage, via a vertical lift by 7 m and transports the goods without pallets into the converting hall via a 195 m long bridge on a direct feeding line.  In this hall, the material can be directly fed to the converting machines or stored in the in-house storage on several levels.

After the realization of this project in several phases, the installation was completed in March 2017. The flexible installation phase was organized in close cooperation with Zerhusen Kartonagen. When the corrugator started its production on December 6, 2016 already, the automatic discharge with the following conveyor technology was also taken into operation. Future modifications such as the extension of the storage were considered in the concept so that a later production increase can easily be realized.

Our sincere thanks go to the management and employees of Zerhusen Kartonagen!  Over the entire period the cooperation was characterized by a pleasant, open and constructive atmosphere.

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