The Dutch plant breeding company Kreling Chrysanten wanted to optimise its cost structure and streamline its production processes. Automation plays an important role in this. Especially as sensitive goods such as plants and flowers are produced cost-effectively and need to have a long shelf life and high delivery quality. With a solution from Lantech, the shipping cartons are now set up automatically.
In 2021, the five largest chrysanthemum growers from the Bommelerwaard region in the heart of the Netherlands joined forces to form the Kreling Chrysanten cooperative. The cooperative's cultivation area is 45 hectares on which up to 140 million ornamental plants intended for shipping are cultivated annually. become. Kreling Chrysanten's customer base includes the largest retailers in Europe. With a targeted Investment offensive in cost-efficient volume production and processing, the cooperative is strengthening its position on the international flower market.
In addition to consistently high product quality, the rapid availability of plants is crucial to the cooperative's competitiveness. An internal review process revealed that the automation of production and packaging lines promises the greatest possible return on investment (ROI). Until 2021, for example, the boxes were still set up manually by two employees. In the meantime, the The three most common carton formats for shipping ornamental plants are erected fully automatically, This has reduced labour costs and increased plant productivity.
The annual production volume of the cooperative has increased by five million plants since it was founded. In response to the increased volumes, Kreling Chrysanten introduced a two-shift system with enormous personnel and administrative costs in order to process the daily production without delays. The However, manual carton erection was monotonous and strenuous work, which resulted in regular interruptions and absences due to illness. In view of the ever-increasing production volume, constant performance of the packaging line was a top priority for Kreling Chrysanten.
„Since we installed the C-1000 carton erector from Lantech, we have been packing more reliably and avoiding downtime. We also save on labour costs.“
Jan Kreling, Managing Director
Thanks to recommendations from other floriculturists, contact was made with Lantech a packaging machine manufacturer with extensive expertise in areas such as carton and tray handling. At an initial meeting at a trade fair, an appointment was made on site and just a few weeks later, the Lantech experts visited Kreling Chrysanten's production facilities. Due to the flexibly changeable carton blank sizes and the high throughput rate of up to 30 items per minute, the C-1000 carton erector from Lantech was the right choice. The machine was integrated into the packaging line at the beginning of 2023. The installation was completed within five hours. For one seamless transition to the downstream filling station, the dispensing roller conveyor was raised.
The C-1000 carton erector combines high performance with flexibility. It can process a wide range of carton and closure types, with carton dimensions ranging from 200 mm x 150 mm x 150 mm to 500 mm x 325 mm x 520 mm. The Carton size range as well as the machine frame, performance data and communication options can be customised to the application, so that Kreling Chrysanten can flexibly produce the three most important shipping formats with just one machine can.
Another advantage of the C-1000 is the reliable right-angled erection of the cartons. The 90-degree angles on all sides are an elementary requirement ensure that the cartons are optimised for the logistics chain and have maximum stability. Cartons that are not square also cause machine jams and production downtime. The nature of the corrugated cardboard, changing temperatures and humidity as well as deviating cutting dimensions can affect the squareness.
From the moment of The blank is continuously checked from the time it is inserted into the magazine until it is dispensed as a fully formed carton with a sealed base. A special pick-up frame pulls the blanks out of the magazine on two sides and forces them into an open and rectangular position. Before the carton is conveyed further, the flaps are folded, making it rigid and keeping it square. A push bar presses the carton towards spring-loaded side belts, which move inwards and outwards to compensate for width deviations and transport the carton towards the closing module.
Thanks to the investment in the packaging line, Kreling Chrysanten was able to Reduce costs and improve production continuity. The amortisation period is estimated at two years. In future, further line components are to be automated in order to fully utilise the potential of the carton erector. „With 15 cycles per minute, we are currently only producing at half capacity,“ says Jan Kreling, referring to the possibility of increasing the capacity. Increase machine throughput to up to 30 cartons per minute with minor adjustments. The cooperative is therefore well equipped to continue its growth trajectory of recent years.
The successful automation of cardboard processing has already prompted the management of Kreling Chrysanten to start further investments and to work together with Lantech again. According to the company, in order to be able to produce for several customers at the same time, a Second C-1000 carton erector ordered. With the integration of the Lantech systems, the cooperative is pursuing a long-term growth plan. „We are currently examining the economic viability of a fully automated packaging robot, which, in conjunction with various Lantech machines, automates the entire production line for our ornamental plants,“ says Jan kreling, looking to the future.
Source: Lantech
