From semi-automatic to fully automatic filling systems: retrofit solutions upgrade machines, make them more modern and are often the more cost-effective decision.
14 September 2018
The semi-automatic K-Dos coordinate filling system including conveyor technology.
(Pictures: Studio12, Greif-Velox)
In the age of Industry 4.0, almost every industrial company is busy digitising and automating its production. Good machines and systems are often several years old and not yet ready for today's requirements. The example of the semi-automatic K-DOS coordinate filling machine for up to 60 drums (200 litres each) or 18 IBCs (1,000 litres each) per hour from Greif-Velox shows how easy the retrofit route can be.
Does tried and tested technology always have to be replaced with completely new, modern machinery? Especially if the machines are still running perfectly, it would be a shame to dispose of them and invest large sums of money in new ones. It is better to see whether it is possible to retrofit the machine. Retrofit solutions upgrade the machines, make them more contemporary and are definitely the more cost-effective Decision.
Example pallet filling system
The system is suitable for bung and clamping ring lid drums or drums that stand next to each other on a pallet, as well as IBCs. Liquids with a viscosity ranging from water-like to viscous can be filled in the chemical, petrochemical, food and building materials sectors. The investment costs for the system are low and are worthwhile for entry-level filling or for filling quantities in smaller batches. In the production flow, however Various processes operated manually, so that this is not fully automated and can be tracked accordingly. For example, the operating personnel take care of the desired filling position and have to open and close the containers manually.
Retrofitted with a camera frame consisting of a camera (in a circle) and lighting equipment, the system becomes an automatic K-Dos-A. (Image: Studio12, Greif-Velox)
Automated production with little effort: thanks to camera technology
If the business model or production size changes, it is more efficient and economical, automate the system. A normal K-DOS then becomes the automatic coordinate filling machine with camera system K-DOS-A, with the same output. Here, the existing system is retrofitted with a camera frame consisting of a camera and lighting equipment. The camera used then creates an image of the containers. Based on this, the associated software calculates the coordinates of the container openings so that the containers are moved fully automatically to the calculated filling position.
Display
This camera is used for EX machines, which is why a flap is provided in front of the camera lens. (Image: Studio12, Greif-Velox)
The Conversion This means that the workload on staff is reduced. The entire system only requires one operator for effective operation, who selects the correct product in the panel. The weight values and container data as well as the information for the camera are then stored there directly. Alternatively, it is also possible to change the grades fully automatically through a control system to be carried out. The system then automatically reports back the individual weight data. Once all the containers have been filled, the pallet either moves out fully automatically or is removed by the operator using a forklift truck.
By modernising and retrofitting the system with a camera system, it is also possible to equip the system with a screwdriver to automatically open and close steel drums with a capacity of 200 litres, for example. This makes it possible to Further automation level realise.
Better service through networking and remote connection
In the course of the retrofit measures, the Control unit of the system and enlarged to a TP 1200. This makes servicing and operating the system easier. The system is also equipped with a VPN or GSM router. This results in decisive Service benefits for smooth operation: Greif-Velox can safely intervene in the function of the system at any time via the system and provide assistance worldwide directly from Lübeck in the event of malfunctions, optimisation requests or other questions. For example, new containers can also be stored together. This approach minimises the number of service calls required, ensuring system availability almost in real time.
Examination and evaluation of the expansion potential
Before any retrofit measures are taken, the Greif-Velox service team evaluates the Expansion potential. This involves checking whether the system can be expanded at all.
„From experience, this is usually the case,“ says Ralph Arndt, Sales Engineer Spare Parts and Retrofit at Greif-Velox. „Systems in EX-free areas are particularly suitable, whereby a ceiling height of over 4.10 metres should be guaranteed,“ he continues.
The experts then examine the extent to which existing components such as the control system or weighing technology can continue to be used. A concept is then drawn up for the realisation, which checks the economic efficiency and sustainability. If the result is positive, a Customised solution provided.
Ralf Drews, Greif-Velox (Image: private)
„As an owner-managed company that is now independent of the group, innovative strength and growth are clearly at the centre of our corporate strategy,“ says Managing Director Ralf Drews about the step towards independence as a medium-sized company.
[infotext icon]Step towards independence as a medium-sized company
Greif-Velox underwent a major change in July. Managing Director Ralf Drews and other members of the management team, together with the Hamburg-based investment company BPE, acquired the company as part of a Management buy-outs vacquired from the previous parent company, Maschinenfabrik Möllers GmbH, Beckum.
„Operationally, nothing will change for our customers, except that they will have to focus on Further innovations and retrofit options can look forward to. After all, Industry 4.0 is right at the top of our agenda with further developments and innovations. In the future, it will make the decisive difference in our customers“ value creation processes. Automated processes are already one of the basic requirements today," emphasises Drews.
The new corporate structure and the focus on Greif-Velox's core competences have created the conditions for continued steady growth.[/infotext]
