Optimising logistics costs: score points with integrated product protection

The fact that the special machine manufacturer WÄCHTER Packautomatik builds complete and complex packaging lines for a wide range of products and industries in the field of end-of-line packaging is nothing new. What is new, however, is that the new technology from the specialist in the furniture sector creates the conditions to optimise the packaging of individual parts - both for batch size 1 and for series production.

In parallel with the general trend towards sustainable packaging solutions and environmentally conscious technologies, the Furniture industry another change can be observed. Driven by rising labour costs and a lack of availability of labour, concepts for automated packaging solutions in general and with a high level of product protection in particular are required.

[infotext icon]With the new Packaging Ordinance from 1 January 2019 are the Requirements for product packaging increased. Sustainable packaging solutions and environmentally conscious technologies are in demand and even have an impact on a company's image: The use of plastic packaging material can be associated with a loss of image, while not using it can be associated with a gain in image[/infotext].

With Take-away furniture a Packaging with various components equipped. These components differ in shape, size, weight and material. Typical contents include furniture components, fittings, screws and assembly instructions. This packaging situation poses two difficulties and therefore places particular demands on process optimisation, as the machine manufacturer points out.

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Firstly: Each individual component has individual handling requirements due to its different properties.
Secondly: Merging large and small-format content often creates unused empty space that is filled with filler material.

Replacement of plastic upholstery materials

WÄCHTER Packautomatik GmbH & Co. KG, Bad Wünnenberg-Haaren, is a traditional, family-run and internationally active company that stands for the quality feature „Made in Germany“. A new feature of the company's concepts for the furniture industry is that the packaging blanks can now also be cut to size using a integrated product protection available.

With the single-material solution, the blanks are provided with incisions and perforations so that when the packaging is erected, the product protection is automatically formed during the folding process or, if necessary, erected separately. This means that No additional packaging materials necessary to optimally protect the product from all sides. This drastically reduces the ecological footprint of these products and at the same time promotes sustainable and efficient production.

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Single part packaging for batch size 1
Customised blanks made from 2-piece continuous corrugated cardboard
Integrated product protection, e.g. for kitchen parts, furniture components, doors

Individual part packaging for series production
Prefabricated 1-piece packaging blanks
Integrated product protection, e.g. for drawer bottoms, carcase parts, fronts, flat formats[/infotext]

An output of up to 30 products per minute in a size range from 120 x 240 millimetres to 1,500 x 2,800 millimetres is possible.

Sustainability through automated and customised packaging solutions

The company combines these new concepts with its proven solutions to enable a fully automated packaging process. Sustainability and scalability are the top priorities here. Sustainability does not just mean the purely ecological aspect. Environmentally friendly packaging material is a basic requirement for the packaging specialist. The focus is also on the economic approach to process optimisation in the packaging process.

Optimisation can be achieved here by Automate packing process and prepackaging take place. Erected cartons are transported along a line of robot cells (or optionally cobots). The individual robot cells are loaded with different components, and the robots in turn pack these components into the passing carton. Small parts such as hinges or individual parts with sensitive surfaces (e.g. fronts) are packed separately in advance.

In addition, pre-packed items can be sent directly to the supplier and only reassembled later with other components (L-shape). Complex packaging processes and logistical procedures are thus equalised and logistics costs optimised.

Scalability of the fully automated packaging system

Another advantage of this concept from WÄCHTER is that the size of the fully automated packaging system can be adapted at any time. The modular design enables both a minimum and a maximum solution and all expansion stages in between, emphasises the special machine manufacturer.

„Reducing packaging materials is the only way to minimise the complexity of the entire packaging process and therefore also the costs.“
Christoph Fromme, System engineer at Wächter Packautomatik.

From a single conveyor belt to a fully automated packaging line, the Customer decide, The customer can decide on the scale in which the automation of their packaging line is to be implemented or the degree of automation can be expanded individually according to the time and financial possibilities. And one contact person is available for the entire packaging process.