A New Zealand company producing plastic jars for the honey industry sought an end-of-line automation solution for their new blow moulding machine. The system was required to remove the jars from the moulding machine, test them for leaks, palletise them, place layer pads between layers and place a plastic frame on top of the finished pallet, then automatically strap the pallet. One of the challenges of this project was the ability to handle multiple jars with different sizes and shapes, round, oval, square and hexagonal.
Apex Automation and Robotics delivered a complete turnkey solution, requiring minimum operator intervention, just loading stacks of pallets at the start of the line and retrieving the complete strapped pallets of jars at the end. Tailored to suit the client’s factory layout, the system includes:
- A pallet dispenser
- Bins for layer pads and top frames
- Takeout system for the blow moulding machine
- Leak Tester
- 6-axis industrial robot with a multifunction robotic head
- Automatic strapping machine
Pallets are transferred from the pallet dispenser to the palletising station on a dual-chain conveyor. Each pallet is then aligned and clamped against a reference point in the palletising station. A 6-axis industrial robot with a multifunction robotic head palletises the jars, row by row as well as handles the layer pads and top frames.
Once the pallet is full, the robot places a layer pad and a plastic frame on the top, before the pallet is transferred to the strapping machine. The automatic PET strapping machine features a side-sealing head on linear rails. When the pallet is indexed into position, the strapping head moves into place, and then feeds, tensions, and seals the strap. This process is repeated twice, after which the strapped pallet exits the line, ready for transport to the warehouse.
The whole line is controlled by a Master PLC that interfaces with the moulding machine, the robot controller, the leak tester and the strapping machine. A user-friendly Human-Machine Interface (HMI) allows the operator to set up products, and perform troubleshooting across the line.
The equipment is fully guarded with perimeter fencing, safety doors and light curtains. The safety circuit includes a programmable safety PLC and several safety zones to allow the operator access the pallet dispenser area or the strapping area without stopping the robot.
Designed and built to meet the production requirements of 24hr a day, 7 days a week operation, the system is continuously producing more than 2000 jars/hr, resulting in significant cost savings to the clients.
