PD_Packaging Digest

Packaging Digest, November 2013

Issue link: http://dc.ubm-us.com/i/207078

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www.PackagingDigest.com NOVEMBER 2013 // BEST PRACTICES higher than our line demands," says Schneider. "We are also able to run a lot of diferent bottle shapes without having to make mechanical changeover on the Emmetis. Tat was huge because we bottle more than 17 diferent brands with multiple bottle shapes." Tese include Tapered, Hock, Claret and Burgundy styles in 187-, 750- and 1,500mL size bottles. Tree Emmeti Model MT 565 systems, one per line, were added starting in August 2011 when the frst was installed on Line 1. A year later in August 2012, another Emmeti was installed on Line 2 along with an Emmeti MT 565 Octopus depalletizer on Line 4. Te frst two systems accept 750mL and 1.5L bottles received in bulk, the Octopus on Line 4 is capable of handling 187mL (airline size) bottles that arrive in reshippers and, in the future, that same size in bulk. Another major requirement was that the Emmeti systems ofer low-level discharge at the required speeds. "It was important to bring the bottles to foorlevel conveyors without some type of lowerator or other mechanism," explains Battaglia. "We have a short distance into our flling processes and also use tapered bottles that are prone to tipping." "It makes for a faster transition from bottle unloading to our fller infeed conveyors," adds Schneider. "We did not have to make any alterations to our line—it was seamless into our process." Te incoming glass arrives on pallets unitized by various packaging materials that must be removed prior to entering the depalletizers; materials include shrink wraps, stretch wraps, bags and various patterns of plastic strapping. Te incoming load varies by vendor and even by plant. On Line 1, the removal or undressing of the pallet is done by a robotic unwrapper/unbagger system from FleetwoodGoldcoWyard that was installed in 2011 with the depalletizer. Te robot is equipped with a heat gun to cut through flms, and a cutter for strapping and bagged loads. Te removed material is subsequently recycled as part of an on-going company-wide program for zero materials to landfll. Usually a truckload of pallet loads, which last for an entire shift, are unitized in one way or another. "Te robot is programmed for that and away it goes," says Schneider. A changeover takes fve to 10 minutes and is basically the fip of a switch, he adds. 23 Depalletizers on Line 1 (top) and Line 2 (above) accept 750mL and 1.5L bottles and meet the Woodbridge Winery's need for speed and reliability as part of a major, cost-saving conversion from reshippers to bulk glass. A third depalletizer installed on Line 4 handles reshippers for 187mL (airline) size bottles and can also accept bulk glass. Te undressed pallets are conveyed into the Emmeti depalletizer where bottles are removed layer by layer. A bottle layer is clamped to maintain positive control before the top layer immediately above is swept of by a sweeping head onto a layer transfer plate that moves up or down to match the height of the layer receiving table onto which the bottles are pushed and released. Te system picks and places the top wood frames and tier sheets to their respective dunnage magazines using a set of pinching metal grippers for the former and suction cups for the latter. Tose materials will also be reused or recycled. One operator is capable of operating any of the three Emmeti systems. Schneider is impressed by how much the machines can compensate for load shifting during transportation from glass vendors in the western U.S. and Mexico. He feels that the Emmeti's engineering and the way it captures, handles and moves the pallets and bottles is "awesome—there's very little room for anything to fall out or fall down. And it does that over and over, all day long." Schneider appreciates that, as simple as it sounds, that the machine does exactly what Emmeti said it would do. "It's repetitive and consistent all day long," he says. "Tey have been durable machines." But he says the best feature of the machinery is that it saves wear and tear on employees. "It speeds production and will for any operation with enough bufering conveyors," he states. In addition to the cost savings in going to bulk, another major beneft has been a reduction in inventory and warehouse space. Smooth installation One of fve box-making machines at the winery form more than 19 different box sizes around a servo-driven mandrel that provides fast, precise changeovers and, more importantly, perfectly squared-up cases. Erected and glued boxes are conveyed on to the servo-driven partition inserters. magenta cyan yellow black One of Battaglia's roles was to specify the controls package, which centered on Allen-Bradley brand human-machine-interface displays and components including variable frequency drives and A-B Kinetic 600 drives, all from Rockwell Automation. Battaglia likes that the HMIs are intuitive, that moving parts are color coded and that safety is secured using pins, locks, guarding and fencing. "When we run their machine, we know it's safe," he notes. Woodbridge added extra grippers and photoelectric sensors as well as HMI machine start/ Continued on page 24 ES347039_PD1311_023.pgs 10.30.2013 03:00 UBM

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