Neptek, together with our international partner Dücker, supply a range of conveyor solutions to the corrugated board manufacturing industry. Our Corrugated Conveyor systems are well engineered, robust and industry proven.
We enable fully automatic transport of the stack from the Corrugator to the intermediate storage and then through the processing machines and onto palletisation and shipment. The material flow and visualisation are fully controlled by PLC and ASCOR (Administration System for the Corrugated Industry).
Throughout the corrugated board manufacturing process, we have the solution for you. The stage of production and technology solution listed below:
DISCHARGE FROM THE CORRUGATOR
Layer Formation using Pusher
Double – in the full sense of the word.
The Stabiltrack® conveyor with integrated longitudinal pusher permits you to form stack arrangements for your format pallets or to double the load units for the transfer car. This increases the through-put enormously. In case of high-performance plants, doubling counters bottlenecks. Depending on layout, shuttle cars can be used as well.
Accumulation
Stack arrangement for your TW loads and your sheet palletising.
Basically, optimal load units should be arranged in order to increase the performance of the transfer cars. In addition, accumulation permits stack arrangement for your sheet palletising.
In this case, individual stacks are separated from the corrugator on to the upstream conveyor in machine direction or are accumulated.
Base Line Turning Unit
Turn by 90 degrees in case of cross flute.
In order to transport stacks with very short cut lengths, so-called cross flutes, optimally by internal logistics, they should be turned before storage in the work-in-progress storage. For this purpose we have developed a turning unit which turns the stack by 90 degrees. Subsequently the individual sub-stacks are accumulated to optimal load units for the transfer car.
Your advantages:
- Higher throughput
- Reduction of the warehouse capacity needed
WORK IN PROGRESS (WIP)
Transfer Car
Rush-hour in your work-in-progress storage – without traffic jam.
The use of high-performance transfer cars sees noticeable movement in your work-in-progress storage. At speeds of up to 3 m/s, which are controlled by the fully automatic control system and visualisation programme ASCOR, the stacks are transported precisely to where they are needed. The highly modern positioning control is used for highly precise fast approach to the target lines. Naturally the emphasis here is safety – with two laser scanners each on the front sides, and correspondingly designed controller stands for manual operation.
Storage Conveyors
Runs and runs …
For gentle transport of the stacks we use our tested Stabiltrack® conveyor, which has been equipped with modular plastic chains made of acetal.
High Bay Storage Solutions (HBS)
Dücker conveyor systems developed a partnership with several well-known high bay storage suppliers. Single deep, double deep, or multiple deep storage are proposed and implemented with cranes equipped with satellites or telescopic forks.
Depending on your requirements, we can provide you a storage for the Work in Progress and/or Finished Goods areas. Our expertise is at your disposal to study in details your production, your need, and the most suitable solution, specifically for cases where surface area is considered quite valuable and building into the height is the only available option.
Consolidated by several projects over the last years, we design and provide all sorts of different High Bay Storage solutions in collaboration with our partners for a Sorting of short, mid and long-term orders according to order prioritisation. With our ASCOR administration system, we supply an integrated high bay module with the capability of tracking and sorting of each stack within your production facilities’ different storage areas.
Hybrid-Intermediate-Storage Systems (HISS)
Dücker conveyor systems GmbH and Westfalia developed a new concept for in particular high storage quantities and new printing technologies.
In order to meet our customers’ requirements, the customised Hybrid-Intermediate-Storage-Systems solution by Dücker and Westfalia is implemented. This combines the decade-long experience by Dücker in the area of Intermediate-Storage solutions and the floor-free high-bay storage solutions by Westfalia.
In this concept the space of a conventional intermediate storage with transfer car and conveyor belts on the ground is used by implementing additional storage above this level. Both systems are connected by the Westfalia Aviator®.
Each project is approached individually according to the facilities’ circumstances.
Machine Infeed
Our designers face every hurdle.
Various aspects have to be taken into consideration when designing the infeed lines. They include various types of machine as well as demanding local conditions frequently or obstacles, such as pillars. But, you can rest assured: With our many years of experience, we will find a tailor-made solution for you. Irrespective of whether turning devices, right angle conveyors or length and cross shuttles are needed, we plan the right elements for you so that this part of the plant is also optimally arranged for your needs.Defined, secure staff crossovers are also part of the optimal safety package. By using ASCOR for control we ensure that the machine is always fed with the requested stack required for the optimal sequence of operation and in the requested direction.
FINISHED GOODS
Pallet Inserter
Pallets only where they are needed.
You profit from the advantages of a pallet-free transport of finished goods by having only one packaging line with a central pallet inserter. Up to two different stacks move into the inserter at the same time and are centred there at the side. Subsequently they are lifted. They are then pushed into the corresponding pallets which are pushed up manually or automatically. Very different pallet patterns can be set up by using pallet robots with turning devices. The plants have been designed in such a way that they can keep up with the performance of the converting machines.
Performance:
- Max. 200 stacks per hour when using a pallet robot
Your advantages:
- High throughput possible
- Various pallet patterns possible
- No empty pallets at the converting machines
- More cleanliness during operation
- Observation of hygiene guidelines in the food industry by very late use of pallets
Empty Pallet Robots
Diligent helper for pallet inserter
The capacity of the pallet inserter depends decisively on the performance of the pallet robot which supplies the various empty or top pallets. Depending on the number of different types of pallet as well as the type of spatial conditions, industrial robots or linear robots are used.
- Performance: 200 pallets per hour
- Max. Pallets: 1,400 × 1,800 mm
The area is secured with a protective lattice. In the pallet feed area, the access is monitored by light grid.
Your advantages:
- Increase in through-put of the inserter
- Reduction of manual effort
Transfer Car
May we invite you to a test drive?
As in the intermediate storage, a high-performance transfer car is required for the transport of finished goods. It is the connecting element between the converting machines and the central palletising and packaging line. Fitted with up to four decks, it can take up up to eight pallets and can pass them on to the packaging line.
At speeds of up to 3 m/s, which are controlled by the fully automatic control system and visualisation programme ASCOR, the high-performance transfer car removes the stack from the converting machine and takes it to the packaging line on the quickest route. Depending on the transported material, so-called hold-down devices can be planned to secure that stacks during quick transport.
The highly modern positioning control is used for highly precise fast approach to the target conveyors. Naturally the emphasis here is safety – with two laser scanners each on the front sides, and correspondingly designed controller stands for manual operation.
SHEET LINE
Pallet Inserter
Here you will learn to appreciate the performance of the inserter.
The best possibility of bringing your sheets on to pallets is by using a pallet inserter. Up to two different stacks move into the inserter at the same time and are centred there at the side. Subsequently the corresponding pallets are lifted and inserted. Very different pallet patterns can be set up by using pallet robots with turning devices. These plants are designed for effective palletising of made-to-measure ware. Their performance corresponds to today’s high-performance corrugators with a working width of 3.3 metres.
We will be pleased to inform you about the efficient transport of your formats. You will profit from the experience which we were able to gain during installation of numerous automatic units all over the world.
Your advantages:
- 200 stacks per hour
- High through-put
- Less manpower
- Various pallet patterns possible
Pusher
Simple and effective.
The best possibility of bringing your format on to pallets is by using a cross pusher. A conveyor with integrated cross pusher pushes the stack on to a lower roller conveyor, on to which empty pallets are placed.
The operator places a slip sheet which is clamped, and which reduces the friction when the stack is pushed. Subsequently this is used as lower edge protection.
Performance:
- Up to 40 stacks per hour
Slip-Sheet Dispenser
Protected all-around
In order to let your products survive the long transport frequently to your customers, they should be packed in an ideal way. This also includes the lower edge protection which is attached fully automatically, and which protects the lower edges of your load whilst strapping. We offer various solutions for laying large-scale base sheets.
