Kacper Ciesielski
Maluka
CHALLENGE
The customer produces protein bars: 360 pieces/min. capacity, horizontal flowpack, packing from 3×1 to 6×5 bars in a bulk carton. This is a new product line in his product line, so express machine changeover time was crucial. Packing bars in cartons on standard machines on the market was too slow for the capabilities of the new line – production was going faster than packing.
The goals set for us are:
– faster carton packing – expected output of 120 cartons/min.
– easy master carton format changes with no packing downtime
– traceability solutions – QR code scanning and data transfer to database
– short timeframe – fastest possible installation, training and commissioning of the machine
“Already after the first talks it was clear that something decent would be created – and it was! It’s exactly what we needed.”
SOLUTION
We offered the customer a modified machine from the TopPack series, which, thanks to our designers’ modifications, was able to form 6 cartons at a time, meeting all requirements for packaging performance. The machine has been retrofitted with an easy-to-use, keyless changeover system, which, once the crew is trained, reduces the real time for format changes to 15-20 minutes. Inside the machine, we installed a QR code scanner and implemented a communication system with the customer’s WMS, ensuring full traceability of the product.
Already during the implementation, the customer changed the formats of the cartons and the lengths of the bars produced. Thanks to the new changeover system and additional tools, the client was able to quickly start production of the new formats – Maluk’s technology proved itself even before the final implementation and commissioning of the project.
Along with the new machine, we supplied a complete conveyor system equipped with a checkweigher, which ensured constant, ongoing quality control and an even smoother packaging process.
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