Solution for Polish converting company
Automatic transport system for JANMAR CENTRUM
2014 we delivered a fully automatic transport system to JANMAR CENTRUM in Poland. The customer is very satisfied with this equipment and is planning further solutions with MINDA.
JANMAR CENTRUM in Trzcinica, a small village in the voivodeship Greater Poland, was founded in the year 2000 as company for the conversion of corrugated paper and they do not have their own corrugator but they buy their sheet plant delivery on the market. They built their first packaging products in rented facilities on a simple die-cutter. Due to high demands, the owner Marcin Gatner decided to build an own factory hall and to buy converting machines.
They deliver the finished products throughout Poland to customers in different industrial sectors: chemical, plastic, automotive, electrical as well as furniture and food industry. JANMAR CENTRUM supplies standard packaging according to the Fefco catalogue as well as special customized cardboard products. According to the “one-stop-shop”-principle (everything from one source) they provide packages of different sizes for various goods, e.g. granulates, deep-frozen food and furniture. Multi-color prints and multipoint-glued folders are part of the product range. Multipart packages are produced automatically and sometimes manually. For this purpose they use a wide range of corrugated paper, going from fine E-flute up to CAA-flute depending on the customers’ requirements.
In 2014 there was an important step for the company’s development. After having purchased an adjacent area, a new building could be realized leading to a total production surface of 20,000 m². Apart from the acquisition of new converting machines, JANMAR also re-organized the material flow. A fully automatic transport system from MINDA was installed, whereby they focused on the finished goods transport in this first step.
Automatic transport system for the finished goods transport
A transfer car collects the blocks from the converting machines and transports them to a central pallet loading station with empty pallet robot, where they are positioned on pallets. After that, they pass through a strapping press as well as a foil wrapper and finally in the dispatch area they are picked up by a fork-lift truck.
A return line allows to transport blocks automatically back to the feeding side for a further production step on a folder gluer.
Thus the operation with fork-lift trucks behind the converting machines could be eliminated leading to better processes and increased security for the personnel. Moreover, the raised efficiency resulted in an increased production.
Continuous shingling stream by two Prefeeders
Another reason for the increased production is the installation of the two new Prefeeders ADVECTOR from MINDA. They allow fully-automatic feeding of corrugated sheets, even of large sizes (up to 3.2 m working width), adjusted to the speed of the converting machine. Thus it is not necessary to lift unnecessary loads as with conventional solutions, as the stacks are not lifted but processed in small packages.
An intermediate buffer ensures that the stream on the shingling conveyor is not interrupted.
The machine provides a gentle product transport by means of a continuous rubber-covered plastic chain.
The throughput rate of up to 24.000 sheets per hour can be achieved by the low installed power.
Two Breaker lines behind flat-bed die-cutters
In addition, behind the two flat-bed die-cutters MINDA breakers MIBREAK are used in order to separate packages, which are die-cut in several stacks, in length- and crosswise direction. As the breaker lines are installed one behind the other, the separating process is decoupled and thus the throughput rate is increased. Pivoting from bottom to top separates the stacks along the perforation line. Hereby the press capacity and the traction are reduced in order to avoid damaged goods. The applied servo technology ensures a pressure repeatability of 100 %. The rubber-covered chain provides a very gentle transport and separation.
By using these two breaker lines another manual working step can be omitted.
The machine investments included a second flat-bed die-cutter, a folder gluer and a printing machine. Due to the new intralogistic system an efficient evacuation of the machines is ensured and thus they are well prepared for the further development on the market.
Automatic central depalletization for intermediate storage
Thanks to the positive experiences with the first step of the transport system installation, the next stage of extension for the automation is just being realized. At present, MINDA is installing a central depalletization where the supplied cardboard sheets are automatically pushed from the pallet and then transported into the intermediate storage by a transfer car. The material flow system MINDA MoveIT organizes the storage on plastic chain conveyors and automatically feeds the corresponding blocks to the converting machines according to the order sequence resp. buffers the material between the converting machines. As a result, it is no longer required to use fork-lift trucks in this production area and safety and efficiency are increased.
At the moment, about 100 employees are working at Janmar Centrum, converting approx. 48 million m² cardboard per year. This volume is to be further increased with the same staff due to the initiated automation.
The owner Marcin Gatner expressly compliments the successful cooperation with the intralogistic specialist MINDA and he will realize future steps, for example further Prefeeders, with MINDA.