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Turnkey Packaging Line for a Metal Fabricator

Turnkey Packaging Line for a Metal Fabricator
Client: Aluminium extrusion manufacturer
Industry: Aluminium Industry
Packaging solutions provided: Wrapping and strapping line
Date of installation: January 2016

Customer Requirement

Our client is a manufacturer of aluminium extrusions, has experienced a recent increase in demand, putting pressure on the logistics & distribution side of their business.

Their packaging process was a completely manual operation, requiring significant human interaction on the production floor. FROMM Australia reviewed their entire packaging process, taking into account human error and safety risks, with a view to automate the wrapping and strapping processes.

Final packaging presentation was also identified as an important area of practical improvement for our customer. They wanted their product to be better presented to their customers and to reduce the risk of products being damaged during transit.

FROMM Packaging Solution

Our recommendation was for a new turnkey process with conveyors, an automatic wrapping machine, plus a strapping machine complete with a robot to place the required bearers.  The client took the responsibility for the conveyors and safety system with FROMM supplying, installing and integrating the packaging equipment.

FROMM Australia engineered an automatic packaging line complete with conveyors, automatic strapping machine, horizontal ring wrapper and an ABB robotic arm.

The easiest way to increase efficiency and increase employee safety is to reduce unnecessary human interactions. An ABB robotic arm was installed and programmed to detect incoming products & automatically apply top & bottom bearers. The robot provided the correct size bottom bearer to the incoming pack. Once stationary the robot placed the top wooden slat and then the FROMM strapping machine applied the strap at the suitable tension setting to stabilise and hold the product. This robot eliminates thousands of human interactions every year, reducing the risk of human error and employee injuries. The FROMM spiral wrapping station applies the cover film to prepare it for local storage and transport.

Overall the new packaging line, provided the following benefits to the customer:

  • Improved throughput of up to 60 pallets per hour
  • Improved safe work environment resulting in a significant reduction in OH&S claims.
  • Redeployment of human resources to more productive tasks
  • Significant decrease in product returns, as the product is now packaged correctly to Australian standards.
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