Cosmetics

Cartoner and palletiser for shelf-ready cartons

Shampoo and conditioner

One F2 robot erects the carton from a flat blank and places it on the Transmodul.

The Transmodul with the erected cartons moves to the loading station. An F2 robot takes four bottles from the grouping table and places them into the cartons.

The cartons are loaded with plastic bottles before being transported to the capping station. The cartons are kept securely in position during all process steps.

The packaging line handles 55 cartons per minute and palletises five layers of cartons. It achieves eight pallets per hour in total.

Requirements

Flexibly cartoned and palletised haircare products

Only 12 metres to a complete pallet

Schubert-Cosmetics developed a line for Nature Organics which helps the Australian company to carton and palletise bottles of shampoo and conditioner in an extremely flexible manner.

Retailers are increasingly demanding shelf-ready cartons with smaller unit quantities. Thanks to a new line from Schubert-Cosmetics, Nature Organics can react to this demand. Schubert-Cosmetics was in fact the only supplier that could resolve all technical requirements within a limited floor space. The performance capabilities and low total operating costs also mean that this line is a sustainable investment.

Solution

How does the solution meet the requirement?

Compact design wins out

The line consists of four sub-machines, which, when put together, have a total length of only 12 metres. Schubert-Cosmetics was able to create such a compact system thanks to the use of TLM technology, which integrates all functions.

At a glance

  • Compact design
  • Quick format changeover
  • High line efficiency
  • Transmodul ensures seamless transport

Quote

“We can further pursue our development with this line. If our requirements change, Schubert can simply replace the corresponding modules.”

Technical Details

The Transmodul for secure handling

The Transmodul is in use to ensure that the cartons are properly stabilised during the entire process. Format plates can be found on the transport carriages for shelf-ready cartons. A robot erects the carton from a flat blank and places it onto the Transmodul. The Transmodul initially moves to the loading station, then stops at the capping station. Two tried & tested F2 robots are in use when closing the glued flap on the inside of the carton lid. One robot closes the carton while the second also presses against the side of it.

The cartoner and palletiser both run very efficiently. Format changeovers are fast, and the line immediately runs at full output again without readjustments even if format parts are exchanged. Another highlight is that the integrated Electronic Service Module (ESM) displays upcoming maintenance work and reports when wear parts have to be replaced. The user is given instructions on how to resolve any problem when an error message appears.

Overall performance
  • 4 sub-machines
  • Two 400 ml and one 500 ml plastic bottle with an oval shape
  • Cartoning 4 bottles each
  • Palletising 5 layers of cartons
  • 55 cartons per minute for all sizes
  • 8 pallets per hour
  • Transmodul in use

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