Oceania Dairy approached RML with the challenge of automating a manual case packing and palletising process. The process includes an operator picking and placing eight 1kg foil pouches of milk powder into RSC shipping cases, and then manually palletising these cases onto a pallet. Within the scope of the challenge, Oceania had requested the track and trace of all pouches from the filling room into the cases, and then onto the pallets, ensuring the traceability of the product throughout the process for quality purposes.
The solution included a customised Automated RSC Top Load Case Packer integrating automated product laning, RSC erecting, robotic loading (via the RML hawk robotic loading system) and tape closing system to load the foil milk powder pouches into the cases and close them for palletising.
During the packing process, the products and cases are tracked through the case packer. The products are scanned as they are loaded into the cases, moved through the closing section of the equipment, checked weighed, and applied with a label that contains the information of each pouch such as weight and other critical production information.
The closed cases are then conveyed to the palletising system where the cases are scanned and collated. An ABB Industrial Robot picks the collated cases from the conveyor and places them on a pallet in a pre-determined pattern. The robot layers the cases on top of one another until the pallet is full. Once full, the pallets are then conveyed to staging zones, collating full pallets that can be called for by the forklift operator if needed, or, collated until the conveyor is full of pallets of cases.
Pallets are fed into the palletising cell as stacks of 10. When a full pallet is completed and moves from the palletising conveyor, the ABB robot locates and picks a pallet from the stack and places it at the palletising conveyor. The ABB robot picks a slip sheet from a slip sheet magazine and places it over the pallet prior to palletising.
Once the pallets have been completed, the traceability data held by the equipment for pouches in cases and cases on pallets is pushed onto the Industrial Control System for quality purposes.
RML have an amazing team of people. They were easy to work with and were happy to assist with any problems we encountered during the design and commissioning process.
We’ve been so impressed by the level of service and quality of machinery that RML have built for us. With such an efficient machine, we’ve had no problem keeping up with production times and demands.
Working with RML on an innovative solution was straightforward. Their in-house expertise in all aspects of the design and build added value to the project delivery process and made some tough challenges easier to overcome.
Our experience working with RML has been positive. We feel we received value for our investment.
The machine provided by RML has to date, resulted in consistent high-quality product for SNPshot Technologies and guaranteed production costs.
We saw a 30% increase in line speed and output as a result of the RML equipment
The trust and reliance that has grown from this project has us achieving numnbers we previously did not think would be possible. We will be searching for opportunities to collaborate with RML in future.
Our integrated, advanced operation ensures the best quality cream cheese is produced consistently.
It was an opportunity to increase the packing line automation, with labour savings offsetting the capital costs.
RML worked with us to understand our requirements and designed a solution to suit our needs. RML delivered an automated system to service two moulding machines producing the Gallagher Ring Top Posts.
We set RML a challenge, design and build a new butter packing machine for a challenging application. RML produced a smart and effective solution that exceeded our expectations.
Ongoing service and support is important to us. RML knew this and I am pleased to say we are not disappointed. I have and will continue to recommend RML to others in our industry based on our experience
IF YOU HAVE A PRODUCTION CHALLENGE,
WE’D LOVE TO SOLVE IT.
