AUTOMATED PALLETISING OF TIM TAMS

In 1996, when Arnott's Biscuits Limited began planning their new manufacturing plant at Huntingwood in western Sydney, they set out to incorporate the latest in manufacturing, materials handling and packaging equipment.

Arnott's looked at several options for the critical case handling and palletising before choosing a robotic palletising solution designed by Robotic Automation Pty Ltd. In 2002, Arnott's have again chosen Robotic Automation to add an additional robot to meet growing demands.

Robotic Automation was able to achieve a solution which takes current and future production data to schedule the robot cell utilisation. This consultation process covered the production scheduling, required software, layout of the plant and methods for achieving maximum throughput.

To minimise teething problems and downtime, Robotic Automation undertook extensive system trials in their Sydney premises before installation.

		The turnkey system, using Motoman robots for the main palletising system including all control and pallet conveying and Colby for the case sortation system, has the following features: 10 product lines feeding to 5 robots Caters for hundreds of different case sizes and numerous palletising patterns with a 1 minute change over Shuttlecars to rapidly transport pallets A.B. Panel View operator touch screens Full integration with plant PLC system Automated sorting and bar code reading No manual handling of product Servo parallel jawed grippers to lift boxes on 4 robots and vacuum on the 5th

This commitment to the customer combined with Robotic Automation's proven ability to tailor a unique turnkey solution was a key factor in Arnott's decision to choose Robotic Automation to design and supply a similar palletising system for their plant in Queensland.

AUSTRALIAN MEAT HOLDINGS

Australian Meat Holdings' facility at Dinmore near Ipswich is the largest in Australia, killing 2,300 head of cattle per day. As part of the expansion in their freezing and handling capacity, Australian Meat Holdings utilise two Motoman SP100 robots from Robotic Automation for palletising.

The robots are located in the cold store area where temperatures approach 0° C and are used to palletise 30 kg cartons of frozen beef. To cater for Australian Meat Holdings' domestic and export requirements, the robots are programmed to palletise a range of different sized cartons into different palletising patterns.

As part of their palletising solution, Australian Meat Holdings require each robot to be capable of palletising up to 6 different products simultaneously. This is achieved via bar code readers which scan the unique barcode on each product. The barcode scanner has many roles; it identifies the product to the robot software so that it can be correctly palletised, and it operates as a built in check; if a barcode is wrong or illogical, the robot will put the product on a reject line. Barcodes are used in conjunction with conveyor sorters to feed products to the correct robot.

The system is broken into 2 separate cells, with each cell containing 1 robot and 6 stations/pallets stacking 6 different products at any one time. The use of separate cells enables routine maintenance and breakdowns to be attended to without halting production entirely. The robots use a tyne gripper designed and engineered by Robotic Automation to ensure a firm grip of the boxes.

The upgrade to automated robotic palletising is part of Australia Meat Holdings complete renovation of their Dinmore site. Previously, they utilised manual palletising. Around 60% of the frozen palletising process is overseen by 1 robot operator.

The system designed by Robotic Automation is flexible and able to grow in line with Australian Meat Holdings' increasing production. Initially, the robots will palletise 2 different sized boxes but will eventually handle 4 different sized boxes. Starting with 2 robot cells, the turnkey installation designed by Robotic Automation has the capacity to expand to 4 separate robot cells.

The system includes a unique shuttle and "park" bench designed by Robotic Automation to deliver empty pallets to the robot and remove full pallets. If a new pallet is moving into place, boxes are stored in the park bench to ensure smooth flow of production. No accumulation conveyors are used in the pick off or infeed roles. The shuttle conforms with height restraints within the facility and incorporates a heavy duty lift mechanism to handle each pallet of 36 cartons, weighing over 1 tonne. Pallets are dispensed from a 2 way pallet dispenser.

Robotic Automation are leaders in palletising technology, with robotic palletising ideally suited to palletising a range of high volume products simultaneously. Through their close association with Motoman, Robotic Automation offer a complete turnkey service; site evaluation, design, supply of all automation equipment including optoelectronic and barcode equipment, installation, commissioning, operator training, and after sales support.

ROBOT WITH A SWEET TOOTH

A leading confectionery manufacturer in Sydney is using a Motoman SV3 robot from Robotic Automation to pick and place individual packets of confectionery.

Located at the end of the production line, the Motoman SV3 picks up 12 packets of sweets at a time and places them into a carton for shipping and display. With its small payload and compact size, the SV3 is ideal for handling delicate lightweight products such as a packet of sweets.

To ensure the product is not damaged, Robotic Automation designed and built a gripper for the robot specifically suited to the customer's requirements with pneumatic suction cups.

The Motoman SV3 is ideal for high-speed "pick and place" work in the food industry where cleanliness and hygiene are critical. The profile of the robot is smooth, making it difficult for particles to adhere to the surface. Also available is the Motoman SV035 which is fully water-resistant and can be hosed down for cleaning and the removal of raw material or residue. The SV035 complies with IP65 industry standards.

The standard motion pattern on the Motoman SV3 can be run in only 0.7s for a 300 mm stroke, the highest speed in its class. This represents a dramatic decrease in handling time and is a new speed record for perpendicularly articulated robots.

Depending on the product, the Motoman SV3 robot can be used for a number of activities. It is ideal for automating case packing (in this case, packets of sweets), tray loading and food handling, all common to the food industry.

The SV3 can be used in conjunction with the Motoman high-speed vision sensor system that will aid efficiency in processes where products come down a conveyor at random. Once the approaching product is seen, the robot will be prompted into action.

The Motoman SV3 comes complete with a Yasnac XRC controller and has the CE marking. The volume of this unit has been halved compared to previous controllers giving it a smaller footprint. To aid ease of operation, users are able to assign function keys to commonly used commands to make work even faster.

Robotic Automation Pty Ltd offers the complete range of Motoman robots, including the SV3, and provides advice, technical support, service and spare parts. Robotic Automation has many years experience supplying turnkey systems to the Australian food industry.

HANDLING OF CHOCOLATE

Cadbury's was established in Australia in 1922 when it opened its first factory in Claremont Tasmania. It is now part of the Cadbury Schweppes global company which manufactures and distributes confectionery in approximately 200 countries worldwide with the plant in Ringwood, Victoria producing Chocolate Bars, Easter eggs and Seasonal Products for Australia and the Asia Pacific region.

Cadbury recently installed a Motoman SV3 Robot for use in the manufacture of the Yowie product.

		According to Richard Taylor Cadbury's Project Manager, "profitability has been improved and the risk of repetitive strain has been removed as a result of the installation". Mr. Taylor went on to say "Evaluation of Cadbury's requirements covered various methods including Cartesian robots however the selection of 6 axis robot was justified because it increased dexterity, reduced tooling costs and allowed more flexibility in the design of the work station. Vision systems were not required because control of the product is maintained the whole way through the process."

"Once it was determined that a 6 axis robot would be used, the project was carried out in house. The selection of the Motoman robot was made on the basis of cycle speed, compact design and cost. The gripper design was determined to be the greatest area of technical risk. This risk was successfully minimised by including it in Robotic Automation's scope of supply."

Cadbury's have just installed a Robotic Easter egg de-moulder just prior to foiling machines; this uses two Motoman UP 20 robots. The Motoman Robot features pre-assigned I/O and made the electrical installation very easy.

Cadbury's started working with Robotic Automation in 1998 and will continue to use their service and spare parts support and would certainly consider their range of products for plant automation projects in the future.

Robotic Automation Pty Ltd are the exclusive distributors for Motoman Robots which can be used for a variety of applications including arc welding, spot welding, palletising, materials handling and machine tending.

Robotic Automation offers consulting advice to clients wishing to develop applications, sales, service, and preventative maintenance contracts supported through its extensive network of National offices.

IT'S A WRAP AT GOLDEN CIRCLE

The installation of automatic stretch wrappers from RA Technologies at Golden Circle's Brisbane distribution centre was part of a recent upgrade, which included a decision to stretch wrap all palletised product prior to it entering the warehouse.

Proven Ability
One of the key reasons Golden Circle chose RA Technologies was its ability to provide local service and backup through trained staff in its Brisbane office. RA Technologies were also familiar with Golden Circle's operations and says Mark Gibson, National Warehouse and Distribution Manager, "We were impressed with RA Technologies' range of equipment, too".

The company famous for canned goods and fruit drink products installed four stretch wrappers - two Robopac HS40 units in the manufacturing area, one for canned goods and one for beverage products, and two Robopac Twist units in the dispatch area, again one for canned goods and one for beverage products.

Satisfaction
Satisfaction with the performance of the Robopac stretch wrappers has led to a fifth stretch wrapper recently being added.

The HS40 wraps at a rate of 85 pallets per hour and the Twist wraps at a rate of 35 pallets per hour. In consultation with engineers from RA Technologies, it was determined that this combination would cater for current production of 150 pallets per hour and dispatches of 1700 pallets per day, and be able to cope with future increases in production. The system includes a pallet identification label being applied to each wrapped pallet.

RA Technologies is part of the RA Group of companies which have supplied world class materials handling, packaging, robotics and automation systems to Australasian industry for over 10 years. With facilities in Melbourne, Sydney, Adelaide, Brisbane, Perth and New Zealand, RA Technologies can provide a high level of service.

PHILIP MORRIS

The Philip Morris Limited Moorabbin manufacturing plant in Melbourne recently underwent a complete upgrade of its manufacturing, materials handling and palletising systems. A sophisticated multi-lane, multi-product, robotic palletising line was designed and installed by Robotic Automation.

The plant employs around 800 personnel and manufactures many well-known brands in a high-speed manufacturing environment. The upgrade had to comply fully with the latest workplace noise and other strict safety regulations, as well as being compatible with the HMI (Human Machine Interface) control system.

Robotic Automation worked closely with Philip Morris in designing a flexible robotic palletising system that easily integrated into the new conveyor system. This final stage of the plant modernisation will be completed with the commissioning of the multi-lane robotic palletising line, which comprises four six-axis articulated Motoman Sk120 robots, a product sortation system, robotic shuttle car and automatic support machinery, including pallet dispenser, taping machine and Robopac stretch wrapper.

A unique seventh axis on the Motoman robots operates as a servo gripper, enabling it to open and close on any carton size while instantaneously allowing each robot to palletises two pallets with discrete product lines. Currently, the line operates at around 20 pallets per hour but has the capacity to operate at three times this speed as the manufacturing output increases.

Each of the four robot cells is operated independently and allows total flexibility in operation and product flow, as one or more cells can be shut down without affecting the operation of the rest of the plant. Each cell has a dedicated Siemens 95U PLC networked to a central Siemens 135U PLC. The entire palletising system is controlled by a SCADA (Supervisory Control And Data Acquisition) program, which was designed and written by Robotic Automation's engineers to conform and interface to the existing sophisticated Philip Morris HMI system.

Using suction pads (a unique solution designed and engineered by Robotic Automation), the robots take the slip sheets from the slip sheet magazine, placing them on top of the pallet layer as required.

Another unique solution designed and engineered by Robotic Automation specifically for Philip Morris' requirements is the shuttle car system that removes each pallet of product as it is completed and replaces it with an empty one supplied automatically from a pallet dispenser. The full pallets are taken by shuttle to a Robopac stretch wrapper or a taping station for securing, and are then discharged to storage and taken away by forklift truck.

FOOD & BEVERAGE AGV SOLUTIONS

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Several of FMC Technologies' standard range of Forked, Unit-load, and Towing vehicles are used in the food industry. A popular application is the block-stack warehousing of product, where the AGV system interfaces with a Warehouse Management System (WMS) to direct each AGV to organise storage of palleted products according to type and access requirements. The WMS then also directs the AGVs to pick pallet orders and deliver them to despatch areas or even directly onto truck trailers.

One specialty application vehicle that is also quite common is used for loading of food and/or trays into sterilizers, as shown in the photo below.

This Automated Batch Retort vehicle is specially designed for the application. It is equipped with gasketed stainless steel body panels giving the vehicle a wash-down capability. Hidden underneath the conveyor deck, the chassis features a drain pan with a remote drain valve to keep the vehicle and floor clean in case of a messy load.

More features include zinc plated casters, splash proof motors, and splash proof external buttons and switches. A clear, flexible membrane covers the operators panel for waterproofing. The vehicle also performs perfectly well on wet or dry floors.

Other FMC Technologies vehicles are well suited to perform general material handling operations within the food industry including raw material storage, raw material transportation, finished goods storage and finished goods transportation to the shipping area.. These vehicles include Outrigger, Reach, Counterbalance, Tug/Tow, Conveyor Deck, Lift Deck, and Narrow Aisle.