A few months ago, Schubert was approached by a German cosmetics company to build a TLM packaging line to cartonise aerosol cans.
Schubert was also able to make it adapt automatically to can size changes. If the TLM robots require another set of tools for an upcoming size change, the tool change takes place fully automatically and behind closed safety doors. This reduces the conversion time to just five minutes, and increases the effective output rate considerably.
This is how it works:
Four TLM sub-machines integrate all the required functions for the production of shelf-ready cartons. The aerosol cans are fed in on one track. There are four TLM-F2 robots and one transmodule section. A robot erects the trays from flat-lying blanks and places them on the waiting transmodule. Another one picks up product patterns and loads them into the trays. The next robot glues a wrap-around blank over the tray as a lid. The fourth two-axis robot transfers the package to the discharge belt.
The tool change begins with selection of the corresponding programming at the control panel. On one side of the fourth sub-machine, there is an empty tool cabinet where the tools of the robots for the size change are placed. The opposite cabinet contains the tools required by the robots for the next size.
The process begins when all products and packaging of the previous format leave the line. A TLM robot in the fourth sub-machine then outfits a transmodule with an adapter. In normal packaging mode, this robot transfers the packets to the discharge belt.
The transmodule moves to one of the TLM-F2 robots. The robot places its tool on the carrier and decouples it. The transmodule moves into the fourth sub-machine, where the robot places the tool on an extended "drawer" of the tool cabinet.
This procedure is repeated until all the robots have given up their tools. All robots are given new tools in a similar manner, one after another. The next packaging size can begin after five minutes. There are no difficulties in starting up, and perfect cartons are guaranteed from the beginning.
As with all components of TLM technology, the tool change system also has a modular design, so Schubert customers can order additional tool sets for new sizes at any time.
The line is currently processing individual 250ml cans and containers with three 400ml cans in shrink wrap. An additional product already considered during the planning phase is a 300ml can. The three packing patterns of the shelf-ready cartons are 2 x 3, 2 x 5 and 2 x 3 containers. The output is 320 individual cans or 107 triple containers per minute.
