Mechanics and electronics in perfect harmony
A market demand to satisfy, a new design to create: together with Bosch Rexroth, Movipack creates a “cost-cutting” casepacker that is unique in its class.
Movipack’s casepacker made in collaboration with Bosch Rexroth: monoblock frame, automatic and compact dimensions, guaranteeing precision, costs optimization and adaptability.
IndraDrive Cs by Rexroth perfectly adapts to the creation of diverse automation architectures.
The idea for a new casepacker arose from a specific request by an important Eastern European can-maker that wished to package more products in cardboard boxes of the same format as those it was already using, with the goal of limiting storage and transport costs. Having taken up the challenge, Movipack began designing a new machine capable of packaging 15% more containers without altering the bulk of the boxes.
Considering how this was a need shared by other concerns in the can-making sector, Movipack then took the opportunity to propose to the market an innovative solution capable of satisfying a growing demand.
The role of Bosch Rexroth
Aware of the fact that, in order to reach this ambitious goal, it was necessary to rely on the support of a reliable automation supplier, one capable of guaranteeing quality and meeting the quality standards asked for, Movipack turned to Bosch Rexroth.
The concern then laid out the most urgent problem to solve for the automation multinational: the casepacker needed first of all to quickly and precisely order the pieces, making the best use of the available space in such a way as to economize packaging and transport costs.
In addition to guaranteeing products of a high quality recognized worldwide, Bosch Rexroth proved a complete partner, not just due to the technology it was able to offer, but also due to its engineering capabilities, which represented a competitive advantage in defining and developing the new machine.
Already from the planning phase, Bosch Rexroth supplied Movipack with its engineers and programmers, offering impeccable consulting on the best products to use and their applications, on subsequent testing and on every step, right up to final testing.
The intervention in practice. Bosch Rexroth’s competency then enabled the creation of a solution that is one of a kind on the market, characterized by maximum repeatability of the requested performance, thanks to a perfect integration of mechanical and electronic components.
The mechanical construction has been simplified by the adoption of compact linear modules, in a screw drive version (CKK module) and dentellated belt drive version (CKR), characterized by reduced bulk, simple assembly and reduced mechanical play, with which a high performance pick and place application can be created very quickly. The use of electro-mechanic cylinder (EMC) linear electric actuators makes it a turnkey solution, characterized by high precision and repeatability in creating linear guides, alternative to conventional pneumatic cylinders with fixed guide.
The use of IndraDrive Cs servo drives is perfectly adapted to the creation of diverse automation architectures, those with multiple axes controlled by Sercos III-based MLC motion logic controller, those with less axes, in which the drives can be piloted directly from a plc through one of the Ethernet-based protocols with which the IndraDrive series drives are supplied (Sercos III, EtherCat, Profinet IO and Ethernet IP).
The integration of electric and mechanical components proved a winning solution in defining both the architectures of low cost machinery, easily integrated with the control platforms requested by end users, as well as the more complex and high performance multi-axis architectures.
The advantages of the new casepacker
Precision, optimization of costs and adaptability: Movipack has thus fulfilled its commitment to creating a solution capable of reducing transport and packaging costs. And the customer, immediately following the installation of the casepacker, reported a 15% increase in products packaged with the same size of box, in addition to a machine efficiency index of 98%.
The time cycle was also advantageous: the machine was delivered just 4 months after the order was written up, including planning, construction, assembly and pre-testing.
Another advantage noticed by the customer was the ease of installation (plug & play), without counting the fact that the compact monoblock frame proves suitable for placement even in limited spaces.
The future. Custom designed to cater to the specific needs of the products and materials produced by the can maker, the new Movipack casepacker is modular and can easily be recreated. Indeed, the builder has not just designed a new product but, making use of the innovative technologies at its disposal, has developed a modular solution that can be repeated and tailored, in such a way implementing a proactive market strategy. After the first automatic casepacker, successfully built and made operational, Movipack is already at work to make the new solution more accessible and adaptable to a wide variety of sectors and industries, so as to take full advantage of its potential as identified in the packaging sector.
FOCUS ON BOSCH REXROTH
Economical, precise, safe and energy efficient: the drive and control technology of Bosch Rexroth (Bosch Group), new machines and installations of any size. Bosch Rexroth supplies worldwide integrated drive and control technologies for industrial installations, mobile operator machines, and technologies relating to the sector of renewable energies and services. It’s the only company to operate in these sectors with an integrated offer capable of satisfying numerous demands, from support and planning to supplying high quality components. Bosch Rexroth can work as a single supplier for hydraulics, electric controls and drives, linear equipment and assembly. With branches in more than 80 countries, the concern generated approximately 5.6 billion euro in turnover in 2014.
MOVIPACK IN BRIEF
A leading Italian concern in the design, construction and setup of industrial automation machinery and systems for packaging and handling, Movipack (BS) was founded in 2012 on the wishes of the Faiella family, making it a player of internationally recognized excellence. Today it exports worldwide projects and installations for food and beverage and can-making generally, processing any material type, including tin plate, aluminium, cardboard, glass, plastic and PET.
Approximately 90% of the company’s business is oriented toward exports, particularly to Eastern Europe, the Middle East and North Africa, leveraging an extensive network of agents and distributors throughout these regions.
The solutions designed and built by Movipack are created for the most part in response to single orders, studying ad hoc applications or taking advantage of standard products to be tailored according to the needs of the customers, typically medium to large concerns and multinationals.
The concern’s Research and Development is constantly working on the development of cutting-edge projects and technologies, or creating new machinery capable of satisfying the needs of customer concerns. Worth recalling, on this topic, is that in 2014 alone, Movipack invested 18% of its turnover in R&D.
