ZENON designed and offered an integrated and fully automated solution that fully met the needs of ATHENIAN BREWERY. The repacking line that was built had the following features:
- Depalletizing of full crates
- Palletizing of empty crates
- Decrating of full crates
- 1st level packaging of bottles into shrinked multipacks
- Coding of multipacks (expiry date, Lot number)
- 2nd level packaging of multipacks into shrinked bundles
- Labeling of bundles (expiry date, description, barcode)
- Palletizing of bundles
- Stretch wrapping of bundle pallets
- Supervision and control system
For the secondary function of the line:
- Case erecting of carton boxes
- Case packing of de-crated bottles
- Case sealing of carton boxes
Three robotic cells were designed and built by ZENON for the needs of the above system: one for the de-palletizing of the full crates and the palletizing of the empty crates, one for the de-crating of the bottles and case packing of bottles and one for the palletizing of the shrinked bundles. It is worth mentioning that 3 existing robotic arms, modified and adjusted to the needs of the project, were incorporated in the system, thus dramatically reducing the cost of the project.
The entire packaging line also consists of: two shrink wrapping machines, a case erector, a case sealer, an industrial ink –jet printer, a label print and apply system, a stretch wrapping machine and a complete product handling system.
Further to the design, construction and integration of the solution, ZENON developed a SCADA system which allows the synchronization and smooth operation of the entire system. This IT system also allows the graphic representation, supervision and control of the line and its productivity in real time, and it provides meaningful data about the production. The design of the solution ensures ease-of-use, adaptability to future needs and high productivity.
The control panels of the system are equipped with touch screens with various capabilities such as error display and graphic presentation of system performance and remote technical support. The system has a variety of production programs preinstalled to cover the needs of different products therefore product changeovers are automatic and immediate without any need to change any settings, beyond the simple choice of the product.
It is important to note that a multi-zone safety system was especially developed to cover the needs of the application thus ensuring its compliance both with CE norms and the customer’s strict specifications without compromising the productivity of the line.