SITUATION
The customer needed a packaging line for 100 lb medical canisters, integrating multiple types of packaging equipment into a tight footprint. The line had to run autonomously, aside from operators loading foam parts and information packets, and assemble and package at a rate of 2 boxes per minute with 100% labeling accuracy.
SOLUTION
Big Sky Engineering built an 8-station case packaging and erecting line:
Case Erector- Erects cartons continuously from a magazine that lets operators load multiple flattened cartons at once, staging each carton before it enters the insertion zone.
Bottom Foam Insertion- A robot picks the bottom foam piece from the foam in-feed conveyor and places it into the clamped, located carton.
Metal Canister Insertion- A Fanuc 6-axis M-10iD robot and 3-axis gantry pick and place the metal canister into the bottom foam insert. Barcode readers capture canister and carton data, and the shipping label is applied at this station.
Top Foam Insertion- The robot picks two top foam parts and places them into the carton.
Case Sealer- Tapes the top edges of the carton before it moves to the out-feed conveyor.
Product Scan- Measurement systems read the carton to verify its contents.
Label Rotate Table- Rotates the carton so the operator can apply documents and mark it good or rejected via hard-wired pushbuttons.
DOT Rotate Table- Scans the carton barcode, rotates it, and applies the DOT label before sending the completed carton to palletizing.
DESIGN FEATURES & SPECIFICATIONS
- Fanuc 6-axis M-10iD robot cell
- Integrated case erector
- Integrated case sealer
- Integrated label applicator
- 3-axis gantry and canister transfer conveyor
- 5-row foam and packet in-feed conveyor
- Carton orientation vision systems and product barcode scans
- HMI with icon-based controls, manual override mode, and live cycle rate/station status display
Machine Dimensions: 24’L x 51’W x 11’H
Power Requirements: 480 VAC, 3-Phase, 60A
Pneumatic Requirements: 80 PSI, 10 SCFM
