Flexible bagging, palletising and packaging of different building materials

Adapting to different building materials without retrofitting

The system can be flexibly adapted to the different materials, no retrofitting required. The individual system components are easy to maintain and operate reliably. This ensures high levels of availability and prevents downtimes.

A mountain range, characterised by the summits of the Chrüzberg, Stauberen and Hoher Kasten, dominates the panorama of the extensive Rhine plains. Here in Sennwald in the canton of St. Gallen, nature enthusiasts, hikers and bikers enjoy the forests, meadows and winding paths. The Austrian building materials manufacturer Röfix, member of the Fixit Gruppe, has one of its five Swiss locations in this picturesque town with its approximately 5,000 inhabitants. “We are manufacturing our entire product range here,” describes Josef Sennhauser, CEO of Röfix, Switzerland. “Among the some 200 different building materials are fine plaster, different types of concrete, masonry mortar, screed and adhesives,” adds plant manager Gerhardt Welte. “Each of these products has very different flow properties.”

This can be a challenge. In order to remain competitive, not only the quality of the building materials is important, but “Manufacturers must also be reliable in getting their products to the customer on time,” Sennhauser emphasises. “One of the most decisive factors for customer satisfaction is staying on schedule.” To achieve this, the Suisse subsidiary needed an adaptable packaging line that could quickly bag, palletise and then package the finished stack with a stretch hood. In the past it had repeatedly incurred downtime on individual machines and workers had to do extensive retrofitting on the line when products changed, which caused delays.

Filling process: not too much, not too little

Due to the wide range of manufactured building materials, we installed a BEUMER fillpac® filling machine that operates according to the air filling principle. The bags are weighed during the filling process. The BEUMER fillpac® is equipped with an electronic calibration-capable weighing unit. It ensures that the bags are always filled with the same amount of material. A special software enables filling spouts and scale to constantly compare weights. By using ultrasound to seal the bags, a very clean and efficient technology, the system can ensure optimal results. It also avoids the accumulation of material around the valve.

Due to its modular design, the system can be easily integrated into existing lines. The added bag placer and ream magazine make the filling system even more efficient. Servomotors automatically, precisely and energy-efficiently drive the application unit and the suction gripper. The gripping and placing system takes the bags from the stack and applies them safely on the filling spout. 1,200 bags per hour can be applied like this with high precision. 1,800 bags are possible by adding an extension. “The bag placer can be easily adjusted to other bag formats by the user. This increases the system’s flexibility,” explains Denis Sielemann, Senior Sales Manager, Building Materials.

Gentle palletising is ensured

For the subsequent fully automatic, reliable and most of all fast palletising, we installed a BEUMER paletpac® layer palletiser. This system precisely stacks the bags layer by layer in a 6-bag pattern onto the pallets. Sielemann explains: “The system includes a twin-belt turning device, so the bags can be turned to the required position fast, gently and without affecting their dimensions. “Regarding the positioning accuracy, this device offers an immense advantage when compared with conventional turning processes.” The system component moves the bags without deforming them from a mechanical viewpoint. Two parallel belt conveyors are used instead. They turn the bags by moving at different speed. The intelligent control of the twin-belt turning device also takes the dimension and weight of the bags into consideration. Exact positioning, specified by the preset packing pattern, is achieved. What makes it unique: The user no longer needs to adjust the system to changing parameters in case of a product change, saving time and money.

A film transport system, which is particularly gentle on the material, introduces the previously cut and sealed film hood into the system. On its way to the crimping and stretching unit, the sealing seam on the film hood cools down so that it can be crimped without losing time. This allows for the elimination of energy-consuming cooling units and efficiency-reducing cooling times. “With the BEUMER stretch hood® A, we can switch quickly between different film types, which increases the flexibility of the entire line,” says Sielemann. “We can process 50 to 60 pallets per hour,” adds Josef Sennhauser: “And this can be still increased if needed.”

The system supplier has equipped this line with the BEUMER Human Machine Interface, which makes it easy and simple to operate. The operators are provided with an easily understandable and intuitive interaction concept, enabling them to define the same efficient working sequences for all machines. Displays help visualise how and where to make the settings. The user can for example call up video sequences that show the changing of the film roll and the film knife. For other set-up work like the bag correction on the BEUMER paletpac®, the operator panel includes graphics and step-by-step instructions.

No downtime, flexible product changes

The packaging line is in operation since the second half of 2016. There has been no downtime since and the employees can easily accommodate product changes, exactly what Röfix wanted. Should any issues occur, the people responsible can always be sure of our support. If necessary, our service employees can quickly and easily access the systems for remote maintenance and provide support.

“We are very satisfied,” Welte summarises. “BEUMER Group provided us with a turnkey solution that runs smoothly.” Sennhauser adds: “Ever since this line has been in operation, we have always been available for our customers. With the new packaging, we can also guarantee added value such as greater load stability and efficient display of the products for an optimal brand presentation.”