08/05/06
Press Release - Automation partners team up to provide advanced confectionery packing solution



In-line with the growing trend for automation within the FMCG sector, Sewtec Automation of Dewsbury, West Yorkshire, has developed a multipack autofeed system for Fox’s Biscuits of Kirkham, Lancashire, an element of which uses two ABB IRB 340 FlexPicker robots.

The initiative for the project came about following audits of the then manual operation, Fox’s management realising that any improvement over the existing manual multipack stacking methods offered real scope for increases in efficiency and reductions in cost. The work was labour intensive and required frequent staff rotation to prevent the risk of RSI-type injuries.

Fox’s engineering project manager Paul Fisher was involved in the sourcing of a fully automated system that had to meet a range of demanding parameters. The system needed to be: (i) easy-to-use with a foolproof control system (ii) reliable (iii) capable of automatically balancing the speed of the two independent product in-feeds with the existing rate of product out-feed, and (iv) able to provide pay-back in under two years.

Mr Fisher comments: “We very quickly realised that the complexities of the project meant that only proven automation integration companies would be approached. Sewtec was one such company that had a solid reputation for machinery and control’s solutions.”

Recently commissioned, the system replaces what was a purely manual operation, automatically stacking multipacks of ‘Rocky’ or ‘Classic’ biscuits delivered from two independent multi-pack flow wrapping lines, into two, or three-stack configurations, and feeding them into a ‘Bumper Pack’ flow wrapper machine.

Sewtec designed a system comprising two servo-driven, vertical racetrack collators; two slat band conveyors; a Siemens-based control system; and two ABB IRB 340 FlexPicker robots.

The FlexPicker robots were chosen because they have a capability to move and orientate objects with speed and accuracy. Regardless of whether the objects are on moving belts, placed at random or guided, FlexPicker is both faster and more efficient than most conventional systems on today’s market with a capability of 150 cycles/min.

Product is delivered to the Sewtec racetrack collators, from high level conveyors, at different rates and the racetracks invert the packs to the desired orientation, while converting the in balanced random product arrival, to a regimented collated output. The racetracks are each driven by two servo motors which work in conjunction to give a divorced input to output capability with a small buffer capacity which allows for level monitoring and automatic speed adjustment of the downstream wrapper.

Product exits the collators on two Sewtec slatband conveyors, which are mechanically linked and driven by a single inverter controlled AC geared motor. Stacked multipacks travelling along the two conveyors are then transferred into the flow wrapper in-feed by the two FlexPicker IRB 340 robots.

The control system architecture, designed and developed by Sewtec, reflects Fox’s standard requirement for Siemens systems, and features a Siemens HMI, which interfaces with a Beckhoff IPC. The IPC runs Siemens Win CC operating software, TwinCAT PC-based ‘soft’ PLC, and PickMaster - ABB’s bespoke ‘picking’ software.

Since installation, Fox’s autofeed system has performed well, carrying out the necessary collating/stacking tasks with the supervision of just the one operator. Four operators were needed for the previous manual operation.

Fox’s appraisal of the multipack autofeed system has been very positive. Paul Fisher sums up: “The Sewtec system is a well thought out and effective solution, which meets the demands of the application in every way. Though the application could have been met through a non-robotic solution, the concept of using ABB FlexPicker robots means that, through their excellent application versatility, they can be readily redeployed anywhere in the factory, which certainly adds to flexibility. Service response since commissioning has been excellent, and the control system is also very sound, providing foolproof operation and ease-of-use at base level, with Sewtec carrying out programming, fault diagnosis and other high level functions.”

Sewtec application’s engineer Steve Levitt comments: “Fox’s laid down a challenge for Sewtec to undertake this project within a technically demanding framework. Through our own control/mechanical/electrical engineering expertise, plus the use of advanced robots from our segment partner ABB, and complemented by mutual confidence and close cooperation between Sewtec and Fox’s engineers, we have designed, developed, manufactured and fine-tuned a system that is advanced and efficient.

Sewtec has had a long and close working relationship with ABB and is a member of the group’s Global Partner Programme, a scheme whereby key partners are provided with the necessary tools and information needed to succeed within an expanding market for robot-based automation. The Global Partner Programme reflects the worldwide trend for modularity within the automated manufacturing industries, which is itself due to the wide availability of high-quality, versatile robots and automation technology for system integrators and OEM’s, from industry leaders such as ABB.


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