The trade magazine for the packaging industry
The trade magazine for the packaging industry
Tobacco company JTI Switzerland wanted to use less energy when applying adhesives to packaging and turned to Robatech for a new adhesive application system. The aim was to save 30 per cent energy - in the end, an even greater reduction was achieved.
Adrian Vonesch, Head of Maintenance & Repairs at JTI Switzerland in Dagmersellen, enters the meeting room. The new Vision S melter is already on the table. The Performa heated hose is on the demonstration trolley. The new adhesive application system is said to save more than 30 per cent energy when melting, conveying and applying hot melt adhesivesays Martin Berli, Area Sales Manager of Robatech Switzerland. JTI's engineering department is also present at the product launch, as the international tobacco group Japan Tobacco International (JTI) pursues a clear sustainability strategy. Environmentally friendly production and energy efficiency are important.
At its site in Dagmersellen, JTI Switzerland produces 47 million cigarettes per day for brands such as Camel and Winston. On six packaging lines, 50 cigarette sticks are packed into each transport carton in two-shift operation. JTI uses melting devices, heated hoses and application heads from a well-known manufacturer to glue the top and bottom carton lids.
After the product presentation, JTI Switzerland is faced with the question of whether a small unit such as the adhesive application system actually offers energy savings potential of 30 per cent. and can hide more.
"In purely physical terms, approx. 0.1 kWh is required to melt 1 kg of adhesive granules. That is always the same amount of energy. The savings must therefore be achieved through the design of the melter, the heated hose and the application head."
Adrian Vonesch
The JTI Maintenance team decides to purchase a Perform field test. The management gives the green light, because self-collected figures provide the best arguments for successful sustainability projects.
The framework conditions are defined in February 2022. A separate electricity meter is installed on the test line. JTI employees record the current adhesive and energy consumption for 14 days of the existing application system in the horizontal cartoner. Robatech then takes advantage of a one-day maintenance window and installs the free test system: a Vision S melter, two Performa heated hoses and two AX Diamond spray heads for bead application. The new application system goes into operation on the same day. Logging is again carried out for 14 days.
"The old system remained installed in parallel on standby. That was a kind of life insurance for JTI. But I knew that the risk of production downtime was low. Our adhesive application systems have an availability of over 99 per cent. JTI Switzerland has already had three Robatech systems for pallet stabilisation in operation since September 2021. They are running smoothly."
Martin Berli, Robatech
In July 2022, JTI dismantles the old standby system. The Robatech system runs perfectly on the former test line.
"We had expected an energy saving of 33 per cent, because we know that Robatech is careful with figures. The fact that we measured 48 per cent less power consumption at the end of the test compared to the other manufacturer's system surprised everyone."
Adrian Vonesch, JTI
For Robatech, it is clear that vision and performa More energy efficiency in industrial adhesive application bring. "Our development team was able to significantly reduce the heat radiation from the melting tank and heating hose using innovative insulation techniques," says Martin Berli. "Performa is no longer as hot on the outside as other hoses, which you really can't touch for long. In addition, Performa is fully insulated at the connection points and we optimise the hose length to suit the conditions on site. This reduces unnecessary heat loss."
Adrian Vonesch's team also realises that Robatech has put a lot of thought into simplifying maintenance and operation when developing the new system components. Six mechanics and six electricians maintain the warehouse logistics, tobacco processing and production systems in Dagmersellen.
"That's a lot of work that is spread over a few people. We rely on the devices having a high level of availability and repairs being carried out quickly. Robatech is just a phone call away. That makes the company attractive to us."
Adrian Vonesch
Adrian Vonesch's young employees find the Vision melter particularly attractive. According to Adrian Vonesch, this is a motivating factor that should not be underestimated: "Vision is modern and interesting. The Employees have fun working with the device. The arrangement of the maintenance-relevant parts is well thought out and the functions are clear. We didn't even need any training, just a short briefing."
The fact that since the field test for gluing the cartons on the former test line 24 per cent less hot melt adhesive required Martin Berli from Robatech mentions in passing. "It's just a question of the optimum setting parameters. Our service team knows these and can set them for every adhesive application system." The test result exceeded all expectations and shows that Even small units such as the adhesive application system can harbour great savings potential.
Source: Robatech
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