Schulz Organic Dairy had transitioned from packing their 1L and 2L plastic bottles, as well as their 1L glass bottles from plastic crates to cardboard boxes. In doing so they required an automated solution to pack the bottles into cases and place the cases onto a pallet. An additional challenge was helping Schulz create a wraparound box that allowed the glass bottles to make the return trip (in the same box) back to the farm for reuse. Schulz also wanted to remove manual palletising from the business which was tiresome and cumbersome for operators.
The case packing solution that we provided for Schulz was an RML D103 Wraparound Case Packer and a Q102 Palletiser. The Q102 Palletising System is a simple two-position palletising cell, ideal for slower lines and has the benefit of a smaller footprint. The heart of the Q102 is an ABB IRB 460-110 industrial robot, with the robot being fitted with an RML-designed and built grip head style effector. The cases are supported under the bottom of the box by a shelf, and the opposite edge of the case is clamped. This type of head was used as the recyclable glass box has a large perforated window on the top which meant vacuum lifting was not an option. The boxes are picked off the supply conveyor and palletised in various formats depending on the SKU being run at the time. Line operators then feed empty pallets into the cell and remove them fully through a managed safety light curtain.
The D103 which is the most commonly produced machine at RML, is a robust flexible reliable machine capable of packing a wide range of products and formats into wraparound-style cases. For Schulz bottles are received in a single file from the filling line, collated into 3 x 2 and 4 x 2 formats, swept into the preerected cases, glued closed and conveyed out to the palletiser. RML integrated inkjet coding inside the D103 to allow Schulz to apply batch and BBF information onto each case.
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.
