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Efficient intralogistics: solutions to optimise end-of-line production flows

August 7, 2018
Technowrapp and Intralogika work and complement one another in complete synergy and don’t just deal with final clients, but also seek to create solid partnerships with system integrators, companies that integrate the wrapping and handling solutions provided by Technowrapp and Intralogika into their own equipment. One such case is that of an intralogistics and wrapping facility made in collaboration with TMC (Tissue Machinery Company) in 2018 and aimed at an important South American group which works in the tissue sector. TMC, an Italian company with twenty years’ experience in producing packaging machines for the tissue sector, turned to Technowrapp and Intralogika to integrate its own provision of palletising robots with a handling and wrapping solution for palletised products. This line was created to manage and replenish four palletising areas, with a total output of 70 pallets an hour. The big challenge in this facility was managing to optimise the flow of load movements, managing the loading operations from 10 workstations and unloading from 6 workstations with a shuttle that can manage up to 642 different missions.  Facility components 4 palletising robots (supplied and managed by TMC) 3 empty-pallet-feeding robots (supplied and managed by TMC) 1 RGV shuttle with two pallets’ positions and a 30 metre track 81 metres of conveyors 9 hydraulic platforms (8 of which have compactors to centre the pallet) 2 P60 rotating platform wrapping machines 2 PLCs + 2 safety PLCs + 4 remote modules Our approach The heart of this intralogistics facility is the RGV shuttle, which is designed to carry out two main tasks. Supplying the four palletising areas with empty pallets: the piles of 15 empty pallets are loaded from outside the line onto two conveyors, and are then loaded by the shuttle and moved to the palletising areas. The distances between the various conveyors entrances have been measured to allow the shuttle to simultaneously serve two palletising areas which are opposite one another (see blue arrows). Moving palletised products from the palletising areas to the wrapping machines: in this case as well, the shuttle can position itself to simultaneously load two pallets from palletising areas that are opposite one another (see green arrows) and then move and unload the pallets in the two wrapping areas in the same way. All the simultaneous tasks are thus handled by getting the distance right between lines that are opposite one another, and between which the shuttle can move to carry out loading or unloading tasks on two different lines at the same time, following a flow optimisation approach. All the software handling logic has been carefully researched by Intralogika to maximise efficiency and facility productivity. To obtain this goal, Intralogika has had to deal with the complexity of optimising loading operations from 10 workstations and unloading from 6 workstations, managing a large number of possible combinations of flow and tasks that have to be carried out. The approach taken at this facility is further complicated by the fact that every palletising area receives the products from

The era of smart intralogistics systems 4.0

September 19, 2017
Let us introduce here an intralogistics system composed of a pallet handling system line and a Technowrapp pallet wrapping machine that we have realised for a customer of ours in the beverage sector. His need was to connect the production line on the ground floor to the warehouse on the first floor by means of intralogistics system coordinated between them by a complex software. In this installation, a central and 4 peripheral PLCs manage and coordinate automatically 4 different missions. Missions 1) Wrapped pallets handling from the production to the warehouse for their storage and shipment 2) Handling of empty pallets stacked in groups of 15 from the warehouse to the empty pallet dispenser 3) Materials supplying from the warehouse to the entire production line 4) Handling of the materials to be disposed of from the production line to the warehouse Installation data and main parts of the intralogistics system Technowrapp pallet wrapping machine by rotating ring Twin Rings E: it wraps and covers the load hermetically Pallet lifter: it carries up and down 2 pallets at a time (6 meters height and 2.000 kg payload) RGV shuttle conveyor: it carries empty pallets to the empty pallet dispenser Empty pallet dispenser: it collects 15 empty pallets and it releases them one at a time depending on the request of the palletizer Labelling machine: it applies a label on the wrapped pallet 2 roller-to-chain transfer devices 3 roller-rotating platforms 29 conveyors 1 central PLC 4 peripheral PLCs i/o (256 in – 272 out) 6 safety areas 20 inverters 300.000 program rows 24h / 6 days a week The real complexity of this installation lies in the software that has the task of managing the various missions avoiding that one interferes with the other, monitoring all up and down movements of the material to and from the warehouse. To ensure an efficient flow of the line, the following aspects have been handled: a) Accumulation conveyor after the pallet wrapping machine: when the line has to accomplish the missions 2-3-4, the flow of wrapped pallets is interrupted and the pallets are accumulated on the outgoing conveyor, waiting for the end of the mission. Once the mission is ended, pallets can resume their way to the warehouse. b) Areas of accumulation of empty pallets: the stacks of 15 empty pallets sent from the warehouse to the empty pallet dispenser are not accumulated only in that device. Two additional areas of accumulation have been created along the line (on the conveyor before the RGV shuttle and on the RGV shuttle itself) in order to guarantee a continuous flow that does not generate waiting times and that satisfies the constant demand of empty pallets coming from the palletizer. c) The system is supervised by six safety areas, so that only the area of interest is stopped in case of emergency, assuring continuity to the rest of the line. d) A central PLC controls the entire system and communicates with other 3 PLCs distributed along the line. One of them is exclusively reserved to the functions of the pre-stretch carriage installed

Technowrapp presents Intralogika at MIAC 2017

September 18, 2017
Technowrapp will wait for you at stand 62. Visit us and discover Intralogika, our new division born to desingn and manufacture intralogistics systems for handling and traceability of loads into production areas. 11-13 Ottobre 2017 – Lucca (Italy)

Shuttles for management of double and simultaneous missions

September 14, 2017
On 2016 we designed an intralogistics system made up of inox conveyors and two shuttle with double load station. This plant was designed for a German customer who works in pharmaceutical sector and his main need was to have a fast intralogistics system able to move trucks (that contain medical equipment) to autoclaves for sterilization and than to warehouse for storage. To satisfy his high production level we didn’t design a system with one station shuttles, because the shuttles has a safety speed limit, but we suggested a different solution: we optimized this plant with double station shuttles programmed for managing loading and unloading of full and empty trucks at the same time. The system with double station shuttles will be twice as fast as the same system with only one station shuttles.

Intralogistics: from virtual to real

September 13, 2017
On 2017 Intralogika designed an intralogistics system for an English customer who works in pharmaceutical sector. Customer’s need was to install an intralogistics system (hardware and software) able to handling trucks that contains medical equipment. The system will become an interface with 7 autoclaves, 12 robotized islands, 4 return lines and a total of 55 pickup and drop-off stations. The functioning of the full automatic configuration of the plant has been tested and adapted to customer requirements through simulation programs. From this simulation we made our purpose: a system composed of 4 RGV shuttles, 470 metres of conveyors and a complex software program managed by 10 PLCs (4 PLC for safety control). This intralogistics system will be develop in 7 steps. The first part is now installed and tested, later implementations will be fully tested in virtual commissioning. In this way the customer has this benefits: – reduction of installation times and machine downtimes; – the customer can both virtually see system operation and request any possible modification of flow, before putting into production.   FEATURES OF THE INTRALOGISTICS SYSTEM

Intralogika inauguration

June 2, 2017
Technowrapp, company that is working in automatic pallet wrapper market since 2002, inaugurates a new business unit, born to studying and manufacturing intralogistics solutions for system integrators. With Intralogika we want to offer a complete range of products and services for end of line sector, integrating the pallet wrapper with hardware and software solutions for a smart intralogistic. The competences that Intralogika can provide range from the simulation of material flows inside the production area to the development of the hardware part, integrated by the software logic. Each step of the project are made by dedicated internal experts, from the first analysis up to the final test. Only in this way we can guarantee Technowrapp standard for our products and services. On Wednesday 31th May 2017, Technowrapp has received customers coming from all around Europe to inaugurate the new Intralogika site and to present the services born to satisfy the new customers’ needs. Watch the video of the event and listen to the opinion of our guests