Presentation

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Presentation

NEW DEVELOPMENTS
GEBRÜDER LEONHARDT – BLEMA KIRCHEIS
ALL IMAGINABLE IS PRACTICABLE
Aue, January 6, 2012
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NEW DEVELOPMENTS
Gebrüder Leonhardt - Blema Kircheis
Current R&D themes:
• De-/Embossing
• Shaping of 2- and 3-piece cans
• Processing of PVC-free compound in TO-/PT-caps
• Direct sealing on and into metal cans
• Direct sealing with tab
• Direct sealing without tab – Push‘n‘Peel Membrane
Further developments and Retrofitting
• KAPPA
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Embossing/ Debossing
GAMMA II Embomax
GAMMA II EMBOMAX®
Impress Metal Packaging with „Drei Wetter Taft“ Power
Haarlack, Schwarzkopf & Henkel
• „Can of the year“ Silver Award Winner 2009 for aerosol cans
• „Best in Metal 2009 – Highly recommended“ by MPA
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Advance in technology and machinery
GAMMA II EMBOMAX®
• enlargement of the base
Development
• system for changing of complete tool sets for new
diameters and embossing themes
Machinery in series GAMMA II EMBOMAX®
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Advance in technology and machinery
GAMMA II EMBOMAX®
• system for changing of complete tool sets for new diameters and
embossing themes
Development
• for 2- and 3-piece cans
• processing of steel / aluminium / composite materials
• optimisation of the tooling radii and embossing depth
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Technical advancement – technique and machinery
GAMMA II EMBOMAX®
• system for changing of complete tool sets for new diameters
and embossing themes
Development
• processing of steel / aluminium / composite material
• performance increase up to max. 600 cpm
i.e. enlargement of the turret diameter to 12 working stations
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GAMMA II EMBOMAX®
• system for changing of complete tool sets for new diamters and
embossing themes
Development
• enlargement of processable can diameters for food and general
cans
i.e. enlargement of the turret with 8 working stations
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GAMMA II EMBOMAX®
• system for changing of complete tool sets for new diameters and
embossing themes
Development
• enlargement of processable can diameters for food and general
cans
• optimisation of the embossing depth
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GAMMA II embomax®
Technical data
100/4
100/6
100/8
100/12
200
300
400
600
4 stations
6 stations
8 stations
12 stations
Performance max. cpm*
Stations per module
Number of modules
stand-alone unit
Products
2-piece and 3-piece can bodies
Can diameter
Can height
max. 45 – 105 mm**
max. 50 – 250 mm**
Material specification
tinplate, aluminum 0.08 – 0.25 mm**, cardboard max. 1.2 mm
De-/Embossing depth
max. 0.5 mm **
* depending on product size and material
** other formats on request
Machinery directive according to 2006/42/EG
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Embossing / Debossing
Marketing activities
Guerilla-Marketing / presentations for end customers
• Increased packaging value through accurate& precision-embossing EMBOMAX®
• Wernesgrüner
• Lorenz Bahlsen
Snack-World
• optical and haptic experience of the brand
• product differentiation
• Heinz
• increase of the product value
• BDF Beiersdorf
Goal: Presentation of new possibilites for can designs considering
new technologies
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Embossing / Debossing
Marketing activities
Sample presentation for BDF Beiersdorf 09.11.2009
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Shaping
Test unit 1
Working principle:
• ends of the welded can bodies are positioned
and oriented in working station
• fluid medium causes expansion of the elastomer
body (inner tooling)
• can body is pushed into mould cavities and
obtains its shaped design while end diameter
remains constant
• manual operation
positioning and
orienting of can
closing + securing
testing device
program run
and discharge
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Shaping
Test unit 1
Realized features :
longitudinal beads /
logos + letters
asymmtric shapes
on circumference
smooth
transitions
interrupted
beads on
circumference
flexible combination of
features according to
customers’ demands
preparation of samples
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Shaping
Test unit 2
Design and Function:
• like test unit 1
• vertical position
• for can heights up to 250 mm
• semi-automatic procedure
• simulation of real-time shaping
Parameters:
• max. shaping time: 0.5 s
• max. pressure:
200 bar
• max. expansion rate: 40 %
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Shaping
Test unit 2
Sample manufacturing / simulation:
• fast tool exchange for different shaping forms
• optimisation of the required pressure (50 – 200 bar) and time
• easy modification of required pressure for expanding the
elastomer part
• testing of forms and their practicability
Example:
• interrupted thread for seaming with a
cap
• finger moulds
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Shaping
Development basic machine concept
Design:
4.
• Single module with turret principle
• 4 or 8 working stations per module
Function:
1. can infeed into the working station
2. transfer, positioning and orienting of can body
3. closing and securing of mould halves
4. pressurization for filling of volume of the inner
tooling and shaping
5. after pressure decrease: tool unlock and
opening of the mould halves
6. removal of inner tooling and ejection of the
shaped can bodies with an exit star
3.
1.
5.
2.
6.
turret with 8 working stations
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SHAPING CANS
Goal: Gamma II can shaper - Technical data
Performance max. cpm*
Stations per module
Number of modules
Products
Can diameter
Can height
Material specification
Thickness
Expansion rate
Pressure rate
* depending on product size and material
** other formats on request
100/4
100/8
200
400
4 stations
8 stations
stand-alone unit
2-piece and 3-piece can bodies
max. 45 – 127 mm**
max. 50 – 250 mm**
tinplate, aluminium
max. 0,25 mm **
max. 40 %
max. 200 bar
Machinery directive according to 2006/42/EG
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PVC-free lining
in TO-/PT-caps
Up to now lining with WBC / SBC / Plastisol
GAMMA III high speed liner
THETA I multifunction machine THETA II multifunction machine
Machine with turret principle, 4 or Transfer press with two stations:
8 working stations
1. lining
Lining with WBC / SBC / Plastisol 2. curling
Principle: rotary
Principle: linear
Products: round ends
TO-/ PT-Caps
other closures
Products: non-round ends
Transfer press with three stations:
1 die-curling: inner contour
2 die-flanging: outer contour
3 lining
Principle: linear
Products: round clamping rings
New Development: Machinery for PVC-free lining according to
directive 2007/19/EG
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RHO II can sealer for metal cans
Direct sealing with tab
SEALING
EMBOSSING
APPLYING A PLASTIC LID
PRE-SEALING
SEALING
FOLDING
DOWN TAP +
EMBOSSING
BLANKING
MEMBRANE
BLANKING MEMBRANE
TYPE:
RHO II can sealer for metal, composite and plastic cans
OPERATION:
sealing flat membranes into/onto prepared metal cans
PERFORMANCE: up to 300 cpm
with up to 8 stations
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RHO II can sealer for metal cans
• replacement of lid – less material is needed
• easy opening
• enhances convenience for consumer
• product can be taken from the can without the risk
of injury
• 100 % deflation of the product possible
• stackable and reclosable with / without plastic cap,
without loading the membrane
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RHO I modular lid sealer
1 membrane blanking
2 sealing, tab bending, embossing
Performance:
non-round up to 300 epm
round up to 600 epm
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2
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2
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Push‘n‘Peel Membrane
Direct sealing without tab
PUSH THE
BUTTON
LATEST DEVELOPMENT FOR
DIRECT SEALED CANS
• new opening method:
PUSH‘N‘PEEL MEMBRANE
• no tab necessary
• with round blank
• easy removal of the membrane
• risk-free removal of the product
DESIGNED AND PATENT PENDING BY BLEMA KIRCHEIS
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features of the new sealed metal can
•
gas-tight sealing surface
•
100% utilisation of the filling volume
•
maximization of the filling volume by innovative
can design
•
inside pressure stabilizes the sealing surface
•
size of sealing surface does not influence the
filling volume
•
stackable without loading the membrane
•
stackable with or without extra plastic lid
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Operations of the prototype unit
PROCESSING OF ALL OPERATIONS IN
ONE STAND-ALONE PROTOTYPE UNIT:
• pre-formed can: heating
• heated can: positioning
• membrane: blanking and deep drawing
• membrane: positioning into the can
• membrane: sealing inside the can
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Preparing cans with GAMMA II modular can maker
welded can body
top side: rolling and
bottom side: flanging
(both sides open)
upper side: necking
or stretch-forming
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Manufacturing process
laminated
membrane foil
scrap
heating
pre-formed can
NEW SEALED
METAL CAN
SEALING
membrane
forming
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Manufacturing process
necking
pre-curling
curling
flanging
can preparation with
GAMMA II modular can maker
heating cans,
blanking membrane,
positioning +
sealing, embossing
sealing with THETA VI
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Basic module for a dual-lane application
COMPONENTS PER INDEPENDENT LANE
1.
heating section
2.
blanking, drawing and sealing
unit
3.
centering station
4.
coil feeder
5.
scrap cutter
6.
embossing unit or inspection
unit (optional)
7.
electrical equipment
expandable
1.
3.
6.
2.
5.
performance
max. 120 cpm
4.
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THETA VI modular metal can sealer
layout for 4-module configuration without
safety enclosure
buffer storage table
heating section
discharge conveyor for
sealed cans
can infeed
4 operation units
scrap collector
coil feeding unit
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THETA VI modular metal can sealer
layout for 4-module configuration with safety enclosure
performance
max. 480 cpm
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Advantages of the new machine concept
• single modules
with full functionality
• membrane manufacturing
and sealing in one tool
• exact membrane placement
without transfer
• modular machine design for increased speed
• independent operating units
• linear can transport system
• minor efforts for can preparation
• approx. 60 cpm per lane = 120 cpm per module
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New Sealed Lid
Advantages of Push‘n‘Peel Membrane for lids
Latest development for lid sealing
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no tab necessary
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risk-free opening and removal of the product
•
with multi-layer membrane, with or without
aluminium
•
integrated opening instruction and advertisement
possible
•
stackable cans without loading of membrane
no problems with transport, filling and closing the
cans
gas-tight sealing surface up to
without any failures!
q=10-7 mbar l/s
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New Sealed Lid
THETA modular lid sealer
MULTIPLE STATION MACHINE
1. magazine
1.
2. 3-wheel separating unit
3. coil feeder
2.
6.
4. tooling area - forming
5. tooling area - sealing
7.
3.
6. lid transfer system
7. press drive
shown without safety enclosure
4. 5.
performance: max.
200 epm
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FAQs
•
Do consumers accept opening into the container?
Yes - other samples exist with opening direction into the product.
•
Milk powder can
•
opening aid is required
•
which needs to be pushed
into the product
injuries can be caused by
the cutting edge
•
foil residue
remaining on the
inner side of the lid
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FAQs
•
Coffee can
•
Beverage can
• lid with integrated opening
device
• unprotected panel is
pushed into the product
• residue remaining on the
inner side of the lid
• unhygienic
• injuries can be caused by
the cutting edge
•
• during consumption
consumer contacts
unclean lid
Multi-layer membrane on glas containers
• opening aid is required
which needs to be
pushed into the
product
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FAQs
• Are there any problems with the cut edge / roll outside the
container?
No - similar to twist-off caps.
• How can a plastic cap be applied to the direct sealed cans?
An adapted plastic cap can be snapped in using the roll.
sealed can with
inner roll
sealed can with
outer roll
can with outer
roll sealed on
the roll
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Innovation Summary
Push‘n‘Peel Membrane means …
… for consumer
more convenience
… for brand owner
unique packaging, eye-catcher at POS
… for filler
no changes, fewer problems
… for canmaker
improved cost efficiency in production
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KAPPA
Further development and Retrofitting
KAPPA
Crank press with automatic
feeding system for
• strips
• coils
suitable for
retrofitting
• sheets
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KAPPA
Products
PKXD 40
PKXD 63
• ends / lids
• corrugated,
conical cans
• clamping rings
• TO-/PT caps
• cardboard
bottoms
• clamping rings
• drawn can parts
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KAPPA
MAIN FEATURES - TOOLING (1):
• active parts in PM steel or carbide
• tools are prepared for installation of the Brankamppress force monitoring device
• strip guidance of high-speed running tools with
pneumatically adjustable brakes
• guidance for tooling with roller cage to increase
stiffness
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KAPPA
TOOLING
MAIN FEATURES - TOOLING (2)
• controlled skeleton cutter integrated into tooling
• Aublé-tooling for high draw ratio possible allowing
for combination of pre-draw and final draw in one
operation
• can tools with trimming function in one operation
possible
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KAPPA
RETROFIT
Brankamp process monitoring:
new drive system for PKXD 63
• suited for retrofit of all presses
• drive features high
reliability and safety
• efficient early warning system
• easy handling and assembly by plug-and-play
function
• display of max. press force, trend monitoring
and quality factors
• high efficiency
• power-saving
• smooth run
• low maintenance
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KAPPA
RETROFIT
• adoption of safety devices to current
standards according to machinery directive
2006/42/EG
• safety enclosure available with safety light
barriers
• hydraulic press overload device available
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Thank you for your attention.
Gebrüder Leonhardt GmbH & Co. KG Blema Kircheis
Visit us at:
www.blema.de
Lutz Enderlein
MANAGER R&D – METAL FORMING
Reimar Friess
GENERAL MANAGER SALES
E-mail:
[email protected]
E-mail:
[email protected]
Telephone:
Fax:
Mobile Phone:
+49 3771 278 240
+49 3771 278 280
+49 173 278 0872
Telephone:
Fax:
+49 3771 278 220
+49 3771 278 241
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Presentation

Transcription

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