Palletless Packaging Lines

Palletless
Packaging Lines
using the Möllers reverse hood
stretch / shrink wrapping system
Palletless
packaging
Palletless
reverse hood
packages
– the cost saving
transport unit
MACHINES
•
PLANTS
•
SYSTEMS
MASCHINES
Palletless
packaging
•
PLANTS
•
SYSTEMS
Filling, palletizing, packaging, loading.
The entire process from a single source . . .
New era of an innovative technology
The palletless despatch unit – now a choice between:
STRETCH- or SHRINK-wrapped !
It started with a visionary idea - eliminating
the transport pallet by using the goods
themselves as the load platform – the idea
of the self-supporting despatch unit, robustly
braced within a sealed enclosure of shrink
film. Möllers engineers developed the
reverse hood shrink system, and brought the
new technology to market.
The reverse hood shrink wrap load has
proved its worth in countless installations in
countries all around the world, proving itself
superior to conventional pallet loading.
because the pallet has disadvantages – high
cost, space requirements, no protection for
the cargo.
There was still one unfulfilled wish –
a challenge which Möllers has successfully
met with the palletless reverse hood
stretch-wrapped package, a robust load unit
with decisive new economic advantages.
–
2–
Palletless packaging lines from Möllers
. . . with all components:
Plant engineering
Eliminating pallet costs is a major saving, but not the only one:
The palletless reverse hood package has multiple
benefits – for both consignor and consignee
The transport pallet has undoubtedly become
an indispensable element in rationalizing the
supply chain and distributing goods efficiently.
But the pallet is a costly logistics tool. Whether
they are disposable pallets or a reusable ones,
pooled pallets or your own, the procurement
costs are high. Then there are significant costs
for transporting and
storing empty pallets.
Inventory managment
and pallet repairs
involve additional
cost, which is often
significant.
The functionality of pallets is also limited in extent;
when pallet loads have to be ruggedized for
transport and protected against the elements,
additional means such as stretch and shrink
hoods have to be used. They also reduce the
effective payload by their own weight and volume.
The palletless reverse hood despatch unit is the
superior alternative in
many applications, with
advantages extending
well beyond substantial
cost savings.
THE PALLETLESS
DESPATCH UNIT
using the
REVERSE HOOD
STRETCH / SHRINK
SYSTEM
A bundle of benefits:
Eliminates all pallet costs
Ruggedized transport loads
Watertight packaging for outside storage
Product protected against dirt and theft
Environment-friendly recyclable package
Now plus: energy and film consumption
greatly reduced, plant throughput increased
Maximum efficiency
Palletless packaging lines from Möllers
–
3–
MACHINES
Palletless
packaging
•
PLANTS
•
SYSTEMS
Filling, palletizing, packaging, loading.
The entire process from a single source . . .
There are five steps in the production of a palletless stretch package
1. Goods stacked. Last layer
(top layer) in a reduced
stacking pattern
2. Base film applied
THE DOUBLE
CLAMP
STRETCH
3. Inner hood drawn
into position
4. Load turned through 180°
The top layer now forms the
base of the load
5. Reverse hood drawn
into position. Load is ready
for despatch
The ultimate in reverse hood technology
New advantages of the
palletless stretch-wrapped load
The energy-saving palletless stretch-wrapped
load, produced without the application of
heat, is the ultimate in reverse hood
packaging technology development.
The highly stretchable Hi-Expander and
Ultrastretch films provide high strength for
the self-supporting packages. The reverse
hood stretch-wrapped package combines
the functions of wrapping and protecting
cargo. This also includes protection against
moisture ingress, contamination and theft.
Step 1: Stack comes
from automatic
palletizer
HSA-Vario transverse stretch hooder
Film applicator
Step 3: Wrap inner hood
Step 2: Place the base
Step 5: Wrap reverse hood
strengthening films
Load pressing
and turning station
Step 4: Upturn load
onto its base
The base film applicator, automatic stretch hooder and
load turning station form the basic unit of the line
The plant technology is mature and reliable,
with the HSA-Vario at its heart: The gusseted
tubular film is supplied from a reel and
reefed onto the four nested stretch fingers,
sealed to a hood along the required length,
separated from the tubular film, then stretched to the wrapping width, and drawn
over the stack covered with the base films.
When the load has been turned, the reverse
hood is wrapped in the same way.
The function of the base films is to carry the
weight of the package contents and to
protect with their high break through strength
the package base.
The base film applicator (left) covers the top layer of the
stack with the base strengthening films. The load
pressing and turning station grips the cargo stack between two conveyor belts, and turns it through180° onto
its base
–
4–
Palletless packaging lines from Möllers
Filling
. . . with all components:
Roto-Packers and in-line packers for
paper and plastic valve bags
Reverse hood stretch loads are ….
... rugged for shipping by road, rail or sea
... ideal for bags and other containers,
... even for high loads and heavy weights
... suitable for transport on open vehicles, with
fast loading and unloading
... storable outdoors in all weathers,
... even at the consignee (customer benefit that
can be marketed by the supplier) . . .
... optimized for minimum film consumption
... made of environment-friendly recyclable material
Flexible in use, secure investment
Reverse hood stretch packaging lines can handle
loads of the most diverse types and formats.
The basic stretch packaging line PSH-1 is equipped with one automatic
stretch wrapping machine, with a throughput of up to 40 units per hour
Reverse hood stretch packaging lines can also
be used to produce normal unsecured pallet
loads and stretch hood pallet loads.
The range includes units with a throughput
capacity of 40 to 100 loads per hour.
This flexibility in use and the cost advantages of the
palletless stretch load makes acquiring a reverse
hood stretch line a well founded, future-proof investment
that soon pays for itself. Beside the conveyors and
the automatic palletizers needed to stack the product,
the basic palletless packaging configuration
comprises just three machine units: the HSA automatic
transverse stretch hooder, the film base applicator,
and the load pressing and turning station.
Patent pending:
EP 2 036 818 A1
Palletless reverse hood
packaging is the
optimum form of
transport packaging for
many stackable goods.
Various stacking
patterns can be used,
depending on the load
format, e.g. for bags
Processing the stretch film hood
1 Reef the hood onto the stretch fingers
2 Stretch the hood to fit over the load
3 Start to wrap the hood
4 Understretch the stack
5-bag pattern with
4-bag chimney base layer
5-bag pattern with
4-bag base layer
1
2
3
4
3-bag pattern with
2-bag base layer
4-bag chimney pattern
with 3-bag base layer
8-bag pattern with
6-bag base layer
10-bag pattern with
6-bag double base layer
Palletless packaging lines from Möllers
–
5–
MACHINES
Palletless
packaging
•
PLANTS
•
SYSTEMS
Filling, palletizing, packaging, loading.
The entire process from a single source . . .
Six steps to prepare a palletless shrink-wrapped load for shipping
1. Goods stacked. Last
layer (top layer) with
reduced pack pattern
2. Inner hood drawn
into position
THE DOUBLE
CLAMP
SHRINK
3. Fork niches profiled
on both sides of the
top layer
4. Load turned 180".
The top layer now forms
the base of the package
5. Reverse hood
drawn over
6. Fork niches reformed.
The unit is ready
for shipping
The mother of all palletless film wrapped loads:
Maximum freedom of choice with
the reverse hood shrink package
With more than 200 Möllers reverse hood
shrink-wrapping lines installed and millions
of palletless packages moving securely by
road, rail and sea – the palletless shrinkwrapped load has been making history for
three decades. Its success is due to its
robustness, its multiple load protection, its
adaptability and its reliable production
process:
Step 1: Stack comes from
automatic palletizer
Combi-FSA shrink wrapping machine
Step 2 + 3: Wrap inner hood, shrink
hood and profile niches
Step 5 + 6: Wrap reverse hood, shrink
hood and reform niches
Load pressing
and turning station
Step 4: Upturn load onto
its base
Above: The PKS-1 shrink packaging unit is equipped
with a Combi-FSA automatic tubular film wrapping
machine with integral shrink frame
–
6–
Palletless packaging lines from Möllers
Stack the goods with a reduced top layer,
wrap the inner hood, form recesses on both
sides of the top layer. Upturn the load onto
its base. Wrap the reverse hood, and reform
the fork recesses – for secure handling by
forklifts and cranes. Load unit is ready to go !
Below: High-performance shrink-packaging line
PKS 2-HL for 90 loads per hour, equipped with two film
wrapping machines and two separate shrink frames
Weighing
. . . with all components:
1
Dosing
Filling
FFS bag filling machines, Pneumatic packers,
Vacuum packers, Screw packers, Dump
weighers, Open-mouth bag filling lines
2
Tailor-made machines – flexible operation
Möllers reverse hood shrink-wrapping lines are
available with a capacity ranging from 20 to 90
packages per hour.
3
Above: 1 Wrapping the inner shrink hood over the load
2 Forming the fork niches in the inner hood
3 Reforming the fork niches in the reverse hood
Shrink-wrapping line PKS-1with integrated shrink frame
By combining various film thicknesses and load
cover formats with full-size or shortened reverse
hoods, with a light cover sheet or with reinforced
base, the system can flexibly adapt to different
load weights and load stresses, whilst minimizing
film consumption.
Möllers reverse hood shrink-wrapping machines
can produce normal pallet loads with or without
shrink hood alternately, as well as palletless
shrink-wrapped loads.
30 years of perfecting the technology
Since its introduction, the Möllers reverse hood
shrink-wrapping process has always been marked by
significant pioneering advances.
Combi-FSA tubular film wrapping machine: One
compact machine for film wrapping and shrinking.
Controlled lamination of inner and reverse hood:
Significantly strengthens the load cover
Standard package designs - material saving variants
Full length
reverse hood
Variable length
reverse hood
Reverse hood
as cover hood
Cover made of
flat film sheet
Contra-laminar technology: Prevents the inner
hood adhering to film-packed product.
Security shrink frame: Satisfies the most rigorous
safety standards of the chemicals industry.
Package designs with reinforced bases
Energy consumption: Significantly reduced.
This history of pioneering development makes the
palletless shrink-wrapped load one of the two highgrade options in the Möllers reverse hood system,
alongside the palletless stretch-wrapped load – two
technology options to choose from depending on the
criteria of your application.
Base bracing
with bottom hood
Base bracing
with bottom sheet
Base bracing with
intermediate sheet
Base bracing with
stacking plate
Both the length of the reverse hood and the film thickness provide effective
means of influencing film consumption and strength of the unit load.
With additional base reinforcement, the reverse hood shrink-wrapped load
constitutes an excellent packaging system, even in extreme applications
Palletless packaging lines from Möllers
–
7–
MACHINES
Palletless
packaging
•
PLANTS
•
SYSTEMS
Filling, palletizing, packaging, loading.
The entire process from a single source . . .
Warehousing free of charge:
Reverse hood packages can be stored outdoors
Open-air storage for reverse hooded loads is variable
in size, pattern and position, and rapidly available as
required
The product is sealed tight in reverse hood
loads, excluding moisture. This eliminates the
harmful effect of water and atmospheric
humidity. This functionality soon earned the
reverse hood wrapped load a second role,
enabling product to be stored in the open.
A flat surface is sufficient; there is no need to
construct a storage building. This technique
has been used in cement works for example
to rapidly create additional storage
capacity with negligible additional expense.
Storing bagged cement in the open through
the winter unharmed has convinced even
sceptics of this additional benefit of the
palletless reverse hood load unit.
Protecting product from dirt and contamination is another function of the reverse hood
load; the sealed load also provides
protection against pilferage. Producers using
palletless reverse hood wrapping can
leverage this welcome user benefit of outdoor
storage as a marketing tool.
Reverse hooded loads with contents resistant to pressure
can be stacked two and more high, providing extensive
storage capacity
The contents of a reverse
hooded load are safe from
rain and snow
Store of bagged
cement temporarily
established on
unpaved surface at a
cement works in South
East Asia
–
8–
Palletless packaging lines from Möllers
Palletizing
. . . with all components:
Automatic Palletizers
Speedy loading of trucks and railcars:
Reverse hood unit loads get moving
Reverse-hood packages are resistant to the rigours of
handling and transport. The tough film cover robustly
encloses the goods, retains the shape of the load,
and resists loading and unloading stresses. The
tightly sealed unit loads thus provide a further
advantage of this unique type of packaging: reverse
hooded loads can be transported on open vehicles,
since they are weather resistant. Open loading
platforms of trucks and railcars are faster to access;
many users have been pleased to find the new
despatch units yield significantly reduced loading
and unloading times.
Open vehicles are well suited to transporting reversehooded packages, and ease of access speeds up loading with forklifts and cranes. Loading from just one
side of the vehicle, with the forklift taking two loads at
a time, makes for especially rapid loading
Palletless packaging lines from Möllers
–
9–
MACHINES
Palletless
packaging
•
PLANTS
•
SYSTEMS
Filling, palletizing, packaging, loading.
The entire process from a single source . . .
Reduced loading times cuts anchorage charges:
Reverse hood packages get
sea freight going
Reverse hood shrink-wrapped loads have
proved the ideal form of sea freight.
Compared to loading loose bags in sling
hoists, they can achieve many times the
loading and unloading rate with fully
mechanized handling, thanks to their
greater volume, precise, stowable shape
with high stack pressure resistance. Reduced
loading times also cut port turnaround times
and demurrage charges. Reverse-hood
packages increase the economic efficiency
of sea freight – not least because they
eliminate the danger of bags bursting and
the consequent clearup time.
Reverse hood loads lend themselves well to stevedoring. They can be handled
by crane using C hooks, double C hooks and shackle harnesses, and also in
belt slings, supporting cooperation between forklifts and cranes
–
10 –
Palletless packaging lines from Möllers
With its excellent handling properties,
the reverse hood package satisfies all
the requirements for rapid loading
and unloading of containers
Shrinkwrapping
. . . with all components:
Combi-FSA Shrink-wrapping machines
Even after long and arduous journeys:
Reverse hood packages arrive in good shape
Sea voyages are not always gentle. But a well
stowed cargo should be able to withstand rough
seas. Reverse-hood packages satisfy this requirement,
with all the features needed to arrive safe and sound
– regardless of how often they are handled, the
means of transport and the distances involved.
Economical
and environment-friendly
Changing climatic conditions – cold and heat – have
no significant effect on the transport and storage
characteristics of the unit loads. Transport and
handling with no loss of product and without
pollution provide economic and ecological benefits,
which the palletless reverse-hood package combines
with the use of pollutant-free recyclable packaging
material.
After thousands of sea miles, the goods arrive
at their port of destination in good shape,
ready to be transhipped for onward transport,
or to be stored temporarily outdoors
Palletless packaging lines from Möllers
–
11 –
MACHINES
Palletless
packaging
•
PLANTS
•
SYSTEMS
Filling, palletizing, packaging, loading.
The entire process from a single source . . .
Möllers stretch-wrap packaging lines: The PSH range
Möllers reverse hood stretch-wrap packaging
lines are available with nominal throughput
rates ranging from 40 to 100 unit loads per
hour. On the PSH-1 line the loads are turned
and then reversed to the automatic stretch-wrapping machine to wrap the reverse hood. The
PSH-K line has a bypass track for returning the
load when the inner hood has been wrapped,
the load is pressed and turned on this track.
The PSH-2 line is equipped with two automatic
stretch wrapping machines; the loads all pass
through the machine in the same direction.
PSH-1 stretch-packaging line
Bag flattening
station
Capacity: up to 40 units/h
PLS automatic slide
plate stacker
Base film
applicator
HSA-Vario transverse
stretch hooder
Stack pressing and
turning station
PSH-K stretch-packaging line
Package removal
conveyor
Capacity: up to 60 units/h
HSA-Vario transverse
stretch hooder
Bag flattening
station
PLS automatic slide
plate stacker
Base film
applicator
Package removal
conveyor
Crossways
conveyor
Stack pressing
and turning station
Crossways
conveyor
PSH-2 stretch-packaging line
PLS automatic slide
plate stacker
–
12 –
Palletless packaging lines from Möllers
Base film
applicator
Capacity: up to 100 units/h
HSA-Vario transverse
stretch hooder
Stack pressing
and turning station
HSA-Vario transverse
stretch hooder
Package removal
conveyor
Stretchwrapping
. . . with all components:
HSA Stretch-wrapping machines
Möllers shrink-wrap packaging lines: The PKS range
Möllers reverse hood shrink-wrap packaging
lines are available with nominal throughput
rates ranging from 20 to 90 loads per hour.
They can be operated with gas or electrically
heated shrink frames, the latter also in a
special safety version. The PKS-1, PKS-K and
PKS-2 models are equipped with Combi-FSA
automatic film wrapping machines with
integral shrink frame. The high-performance
PKS-2 HL line uses two FSA automatic tubular film
wrapping machines, each connected to a
separate shrink frame.
PKS-1 shrink-packaging line
Capacity: up to 20 units/h - Electric heating
up to 25 units/h - Gas heating
Bag flattening
station
PFS automatic
stacker
Combi shrinkwrapping
machine with niche profilers
PKS-K shrink-packaging line
Stack pressing and Package removal
conveyor
turning station
Capacity: up to 30 units/h - Electric heating
up to 40 units/h - Gas heating
Combi shrinkwrapping
machine with niche profilers
Bag flattening
station
PLS automatic
stacker
Package removal
conveyor
Crossways
conveyor
Stack pressing and
turning station
PKS-2 shrink-packaging line
PLS automatic
stacker
Capacity: up to 40 units/h - Electric heating
up to 60 units/h - Gas heating
Combi shrinkwrapping
machine with niche profilers
PKS-2 HL shrink-packaging line
PLS automatic
stacker
Crossways
conveyor
Tubular film
wrapping machine
Stack pressing and
turning station
Combi shrinkwrapping
machine with niche profilers
Package removal
conveyor
Capacity: up to 55 units/h - Electric heating
up to 90 units/h - Gas heating
Shrink frame with Stack pressing and
Shrink frame with
Tubular film
niche profiler
wrapping machine
niche profiler
turning station
Package removal
conveyor
Palletless packaging lines from Möllers
–
13 –
.MACHINES
Palletless
packaging
•
PLANTS
•
SYSTEMS
Filling, palletizing, packaging, loading.
The entire process from a single source . . .
When a name is a benchmark:
The many features of Möllers quality
Feature - Optimum drive
design: the rack-andpinion drive of the
stretch arms on the
HSA-Vario stretch hooder proved to be the
best solution: high efficiency, low maintenance, very quiet
Feature - Compact
format: small footprint
with good accessibility is
typical of Möllers plant.
Even the double head
variant of the HSA-Vario
stretch wrapping
machine for two types of
film only slightly exceeds
the compact depth of the
standard model
Feature - Ease of maintenance: the drives
and control system valve clusters are
grouped at a readily accessible point to
facilitate access as required
–
14 –
Palletless packaging lines from Möllers
Feature - Quiet running:
this feature contributes to
high plant availability
and long service life,
and involves judicious
utilisation of machine
mass. Möllers machines
are mainly constructed of
solid rolled steel sections
“It is the M of palletizers . . .“ –
When world-class products acquire
a reputation for excellence, they are
often quoted as a benchmark. In
this context the letter M stands for
Möllers of course, but sometimes
people like to replace our name
by a German make of car which
enjoys the worldwide highest
reputation. We accept this market
assessment, since it is based on
strict adherence to a level of quality
that certainly bears comparison
with the premier league of German
industry. In all aspects of our work
– in researching market needs,
developing more efficient systems,
designing and manufacturing our
products, and serving our customers
– we aspire to excel. There are
examples and features that testify
to our consistent success in this
endeavour.
Controlling
. . . with all components:
Monitoring
Service
For a clear overview of your packaging operation:
Producat® keeps tight control of stretching and shrinking
Producat® is the control and monitoring software
developed by Möllers for managing the entire filling
and packing plant of any size from a central terminal.
Producat®also supports linking to master systems (host
computers), and can be connected to company
intranets via its Internet capability, so that order
processing and plant diagnosis can also be handled
from other authorized computers. Producat® runs on
a standard PC networked to the machines’ PLCs.
Producat® is structured in several program modules for
displaying information and inputting commands.
Producat® acquires machine data at control level, and
processes it for the data management level
Module A: Order processing
Module A enables production orders to be entered
by accessing complete product data records in tabular
form at the click of a mouse. All necessary machine
settings are made automatically without error.
Module B: Plant diagnosis
Module B provides parameter overviews and
zoomable layout images displaying all actuators and
sensors, to enable monitoring of plant operations.
Faults are rapidly located by flashing or colour coding
of the actuator / sensor signals.
Order processing module: Complete product data records
can be accessed at the click of a mouse, this way all
necessary machine settings are activated automatically
Module C: Software maintenance
Module C is used for basic system settings and for
online updating of system software via the Möllers
teleservice, and for remote diagnosis via the Möllers
teleservice as required.
In the graphic overviews of the plant diagnosis module, the
sensors and actuators are displayed as coloured signals that
facilitate fault location by colour coding or flashing
Palletless packaging lines from Möllers
–15 –
Machines · Plants · Systems
Planning, development and manufacture of complete plants
Everything from a single source
Filling plants for
bulk, liquid and
pasty products
Filling
Shrinkwrappping
Palletizing plants
Palletizing
Palletizing and
depalletizing robots
Palletless
packaging
Loading
Palletless
shrink/stretch
packaging plants
Conveyor
and loading systems
Conveying
Bag loading
machines
Stretch film
packaging plants
Stretchwrapping
Fully automatic
truck loading
systems
Shrink film
packaging plants
Bag loading systems
Loading
Controlling
Monitoring
Control
and visualization
systems
Manufacturing plants of the Möllers Group:
Subsidiaries of the Möllers Group:
Mollers North America Inc.
5215 – 52nd St. S.E., Grand Rapids, Michigan 49512 / USA
Telephone +1 (616) 9 42-65 04, Fax +1 616 9 42-88 25
[email protected], www.mollersna.com
000 „Möllers Intertec“, ul. Giljarowskogo, d 39, office 301-304
Moscow / Russia
Telephone/Fax +7 495 780 97 50
[email protected]
GREIF-VELOX Maschinenfabrik GmbH
P.O. Box 12 11 51, 23532 Lübeck / Germany
Kronsforder Landstraße 177, 23560 Lübeck / Germany
Telephone +49 (0) 451 53 03-0, Fax +49 (0) 451 53 03-233
[email protected], www.greif-velox.de
Möllers Singapore, Singapore Representative Office, # 10 – 09 Golden Mile Tower
6001, Beach Road, Singapore 199 589 / Singapore
Telephone +65 6 298 9860/9817 6880, Fax +65 6 298 9289
[email protected]
Logdos Liquid Filling
P.O. Box 12 11 51, 23532 Lübeck / Germany
Kronsforder Landstraße 177, D-23560 Lübeck
Telephone +49 (0) 451 53 03-0, Fax +49 (0) 451 53 03-233
[email protected], www.logdos.de
Librawerk Maschinenfabrik GmbH
Vossenkamp 1, 38104 Braunschweig / Germany
Telephone +49 (0) 531 370 98-0, Fax +49 (0) 531 370 98-88
[email protected], www.librawerk.de
NATRONAG Maschinenfabrik GmbH
Vossenkamp 1, 38104 Braunschweig / Germany
Telephone +49 (0) 531 370 98-0, Fax +49 (0) 531 370 98-88
[email protected], www.natronag.de
Möllers France, 14, rue de la Papeterie
67310 Wasselonne / France
Telephone/Fax +33 3 88 87 29 00, Mobile +33 632 98 2452
[email protected]
Möllers (UK) Ltd., Maxron House, Green Lane, Romiley, Stockport
Cheshire SK6 3JQ / Great Britain
Telephone +44 161 406 9824, Fax +44 161 494 5982, [email protected]
Möllers Prague, Nad Rokoskou 14,18200 Praha 8 / Czech Republic
Telephone +420 2 8468 2462, Fax +420 2 8468 0499, [email protected]
Möllers Brazil, Via Anhanguera km 14,5 - Vila Mangalot,
05000 São Paulo / Brazil
05.2009/2,0 E/Ry/Fe
Maschinenfabrik Möllers GmbH · 59269 Beckum/Germany · Sudhoferweg 93-97 • 59247 Beckum/Germany · Postfach 1764
Telephone +49 (0)2521 88-0 · Fax +49 (0)2521 88-100 · [email protected] · www.moellers.com