Manufacturers of profiles and jambs face countless challenges in packaging, not only related to the dimensional variability of the products, but also to the complexity of managing the process. In particular, forming custom-length boxes often requires the involvement of two people, further complicating logistics. Warehouse space management becomes difficult due to the need to store large quantities of pre-formed boxes, which are often manually adapted to the product, affecting the final packaging quality. This lengthens packaging times, increases returns and labor costs, and decreases productivity.
The introduction of automated and customized packaging solutions marks a significant shift in addressing these challenges. Using technologies capable of creating tailor-made boxes simplifies product handling, optimizing timing and reducing the personnel required. This not only improves overall efficiency, but also eliminates the need to store boxes of various sizes, reducing costs and waste.
In this article, we will examine a highly automated system installed at one of our customers’ facilities, highlighting how it has simplified the packaging process.
Example of automation for packaging jambs and profiles
Objectives:
- Facilitate packaging operations. Since the products are long, narrow, and heavy, packaging required two operators. The shape of the box required two people to form it along its length, and the considerable weight of the products did not allow handling by just one person.
- Consequently, it was also necessary to increase productivity.
- Optimization of packaging dimensions.
Thanks to a highly automated system for producing tailor-made boxes:
- An inclined product-release conveyor was installed to bring the profiles to a suitable height for the operator, facilitating manual insertion into the box. In addition, with the introduction of the box-forming jig, this operation can now also be performed by a single operator.
- Thanks to the automation implemented, the customer increased productivity from 1 piece per minute to 4 pieces per minute, freeing up one operator to be assigned to other departments in need of efficiency improvements.
How the system works
The automated packaging system for profiles and jambs consists of several stations designed to optimize the entire process. The loading station uses a transfer conveyor that moves the profiles to a 90° roller table, where the products are transferred onto an inclined belt that facilitates manual insertion into the boxes by the operator. An EVO packaging machine produces tailor-made boxes, which are transported to the coupling station. Here, the operator places the box into a forming jig, manually erecting the sides, while the profiles are inserted into the box. The next station handles automatic longitudinal gluing with Hotmelt, ensuring secure and precise packaging. Finally, a system of rollers and belts transfers the packaged product to the unloading station, completing the process efficiently.
Packaging flow for jambs and profiles
