DARWIN&ANTARES_ver.16.05.2022-VERSIONE-ISSUU-TCAPPAPEN2206

UNCONVENTIONAL PACKAGING SOLUTIONS FOR THE TISSUE INDUSTRY 1. DARWIN is a system for Primary and Secondary packaging 2. MODULARITY & CONFIGURATION 3. ANTARES is a system for Secondary Packaging 4. FLEXIBLE MULTI PRODUCTS LINE 5. INTRALOGISTIC- FAST TRACK 6. Interactive Video Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

Code:TCAPPAPEN2206

DARWIN - A new Chapter for the Tissue Industry Fully controlled by only one brain  100% production is inspected and checked with this new packaging solution from log-saw outfeed up to the palletizer

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2

COMPARISON AND ADVANTAGES DARWIN

1. More compact footprint

2. Fewer operators on the line

STATE OF THE ART

1. From 80 meter to 67 with a saving of around 300 square meters (see CASE HISTORY)

3. Integrated systems with centralized controls – 1 PLC

2. Up to 5 operators

5. Reduced number of machines on the line

5. From 7 machines to only 3

4. Modular systems with independent units

6. 99% product changeover done from HMI

7. 100% product quality control with automatic inspection system with Quatis technology 8. Reduced waste

9. More up time The system continues working even with a picking station down

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3. Are used 7 PLC

4. Many stand alone machines from different suppliers 6. Changeover in each 7 machine

7. Quality checked from time to time and randomly 8. Average 0.1 up to 2 % of waste products

9. If one packaging machine stops the complete system stops

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3

DARWIN

MODULES & STATIONS 1.

2.

3.

4.

5.

6.

7.

8.

9.

Metering unit station Controll station Single Robotic Station Multy Robotic Station Bundler Station Multi layer Poly bag Station from Bag for poly reel or premade poly bag Station Premade infeed Paper bag Station Case Packer Station Palletizzing Station

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4

METERING UNIT STATION

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SINGLE ROBOTIC CELL STATION

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5

DOUBLE ROBOTIC CELL STATION

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PREFORMING STATION

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6

BUNDLER STATION & MULTILAYER

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7

POLY BAG FORMING STATION – POLARIS

• • • • • •

Unwind Cut Welding Pick & place Vacuum belt table Bag storage

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8

PAPER BAG FORMING STATION – POLARIS

• • • • • •

Unwind Cut Welding Pick & place Vacuum belt table Bag storage

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POLARIS PAPER BAG ROLLS POLARIS PAPER BAG FOLDED STRENGTH TEST PAPER BAG Return to Index

9

CARTON CASE STATION – FROM EMPTY TO FULL CASES

Pallets cases storage – Cases erector

Pallets cases storage – Cases erector

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10

ANTARES

PACK & PALLET SYSTEM FROM SECONDARY PACKAGING UP TO PALLETS PROCESS & TECHNOLOGY ADVANTAGES

Providing a modular system, flexible and easily configurable to match market need variations Flexible output with different kind of packaging (poly film, pre-made bags, carton boxes, etc.)

Higher production line availability Higher flexibility, reducing changeover times and modality Reduction of human factor impact on format regulations and quality (higher automation).

The line operator must be considered as a process supervisor • 100% Quality control during all the process phases; control systems integrated into packaging machines • Increase of active/passive safety and ergonomics for operators • Free access to all devices • • • • •

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11

ANTARES – TECHNOLOGICAL ADVANTAGES • Through the use of robotic systems and integrated automation it is possible to get: •

An increase in machine availability thanks to the transition from traditional, mainly mechanical, technology to robotics.

•

The reduction / elimination of changeover times (increase in flexibility)

•

Reduction of the impact of the human factor on the process (Adjustments automation)

•

Transition from the principle of “product moving” to the concept of “product handling”. (Quality increase)

•

Flexible configuration of the bundles, due to the orientation in 2 directions (optimization of the pallet layers)

•

Increased stability of pallets, with adaptation to the needs of automatic warehouses

•

Increased speed and flexibility for small formats (CASH & CARRY)

•

Possibility of managing even simultaneous packaging in plastic film / bags and cardboard boxes with the same machine

•

Reduction of foot print, in combination with the palletizing area

•

Reduction investment in palletizing device

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12

ANTARES – EXAMPLE 13643 COMPARISON

With ANTARES

STATE OF THE ART

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13

ANTARES – EXAMPLE 17683 COMPARISON With ANTARES

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STATE OF THE ART

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14

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With ANTARES

ANTARES – EXAMPLE 17890 COMPARISON STATE OF THE ART

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ANTARES – EXAMPLE 18359 comparison

With ANTARES

STATE OF THE ART

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16

ANTARES

MACHINE INSTALLED IN 2018 IN ITALY PACKS 12R

DOUBLE ROBOTIC CELL STATION

PACKS 4R 6R

SINGLE ROLL

BUNDLER EXIT

DOUBLE PICK UNIT

DOUBLE ROBOTIC CELL STATION BUNDLER AND MULTILAYER STATION

STRENGTH TEST POLY BUNDLE STRENGTH TEST PAPER BAG

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17

ANTARES – SECONDARY PACKAGING PERFORMANCES UP TO 200 PRODUCTS MINUTE PACKS

Toilet paper

Kitchen rolls

Rolls per pack

Pack type

SINGLE PICKING

DOUBLE PICKING

Packs per minute (up to)

Packs per minute (up to)

1 robot

2 robots

3 robots

4 robots

1 robot

2 robots

3 robots

4 robots

3

30

60

90

120

54

108

162

216

2

30

60

90

120

54

108

162

216

1

30

60

90

120

54

108

162

216

24

20

40

60

80

NA

NA

NA

NA

16

20

40

60

80

NA

NA

NA

NA

12

20

40

60

80

NA

NA

NA

NA

9

20

40

60

80

54

108

162

216

6

30

60

90

120

54

108

162

216

4

30

60

90

120

54

108

162

216

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18

FACE FACE DRP

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ANTARES – NESTING LAYER CONFIGURATIONS EXAMPLES

19

ANTARES – SECONDARY PACKAGING BUNDLER & CASES – SIZE C

A

B C A

C

B

A: 200 – 760 mm (8” - 30”) B: 200 – 510 mm (8” – 20”) 350-800 (14’’-31’’) - optional

C: 200 – 355 mm (8” - 14”) 200-500 (8’’-31’’) - optional

UP TO 20 BUNDLES/MIN Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

A

B

A: 200 – 600 mm (8” - 23”) B: 350 – 800 mm (14” – 31”) C: 200 – 610 mm (8” - 24”)

UP TO SPEED 15 CASES/MIN Return to Index

20

ANTARES – PREMADE PAPER AND POLY BAG PACKAGING – SIZE

A C B

A: 200 – 800 mm (8” - 30”) B: 200 – 510 mm (8” – 20”) C: 200 – 350 mm (8” - 14”)

UP TO 18 PAPER BAG /MIN Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

A: 200 – 600 mm (8” - 23”) B: 350 – 800 mm (14” – 31”) C: 200 – 355 mm (8” - 14”)

UP TO POLY BAG 18 /MIN Return to Index

21

ANTARES – 100% PATTERN OPTIMIZATION IN ALL CONFIGURATIONS FOR BUNDLES,

CASES, PALLET BOTH WITH WRAPPED AND UNWRAPPED PRODUCTS

PALLET US-UK

NESTING TOPVIEW

NESTING OUTFEED

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NESTING OUTFEED TO PALLET Return to Index

22

ANTARES PUZZLE

DIFFERENT POSSIBLE MACHINE CONFIGURATIONS 1. BUNDLER

2. BUNDLER & PALLETIZER 3. CASE PACKER

4. CASE PACKER & PALLETIZER

5. BUNDLER- CASE PACKER & PALLETIZER 6. BUNDLER -CASE PACKER- SQUARE DRP

7. CASE PACKER -POLY REEL BAG FORMING

8. CASE PACKER- PREMEDE POLY BAG & PREMEDE PAPER BAG

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23

1 ANTARES – CONFIGURATION BUNDLER The system can: 1. Create the layer to make 2-layer bundles and bundles from poly coming from 40 up to 60 micron thinkness plain bobines 2. Prepare the layes for the pallets with the products that need to be palletized without secondary packaging

BUNDLE OUTFEED Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

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24

2 ANTARES – CONFIGURATION BUNDLER & PALLETIZER

The system can: 1. Create the layer to make 2-layer bundles and bundles from poly coming from 40 up to 60 micron thinkness plain bobines; 2. Prepare the layes for the pallets with the products that need to be palletized without secondary packaging 3. Make the pallet and wrap it

BUNDLE OVERVIEW BUNDLE TOPVIEW Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

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25

3 ANTARES – CONFIGURATION CASEPACKER The system can: 1. Create, fill and close the cases with tape or glue; 2. Prepare the layes for the pallets with the products that need to be palletized without secondary packaging

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26

4 ANTARES – CONFIGURATION CASEPACKER & PALLETIZER The system can: 1. Create, fill and close the cases with tape or glue; 2. Prepare the layes for the pallets with the products that need to be palletized without secondary packaging 3. Make the pallet and wrap it

TOPVIEW Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

OUTFEED TO PALLET Return to Index

27

5 ANTARES – CONFIGURATION BUNDLER- CASEPACKER & PALLETIZER The system can: 1. Create the layer to make 2-layer bundles and bundles from poly coming from 30 to 60 micron thinkness plain bobines; 2. Create, fill and close the cases with tape or glue; 3. Prepare the layes for the pallets with the products that need to be palletized without secondary packaging 4. Make the pallet and wrap it

CASE BUNDLE

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28

6 ANTARES – T-CONFIGURATION BUNDLER- CASEPACKER & SQUARE DRP

CASE BUNDLE DRP FACE PALLET FACE ROBOT

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29

7 ANTARES – CASEPACKER - POLY REEL BAG FORMIG

The system can: 1. Create the layer to make Bundles from poly coming from 30 to 60 micron thinkness plain bobines; 2. Create, fill and close the cases with tape or glue; 3. Prepare the layers for the pallets with the products that need to be palletized without secondary packaging

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30

8 ANTARES – CONFIGURATION CASEPACKER PREMEDE POLY BAG

& PREMEDE PAPER BAG

The system can: 1. Create the layer to make bags from paper; 2. Create, fill and close the cases with tape or glue; 3. Prepare the layers for the pallets with the products that need to be palletized without secondary packaging

POLARIS PAPER BAG ROLLS POLARIS PAPER BAG FOLDED STRENGTH TEST PAPER BAG Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

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31

EXAMPLE OF FLEXIBLE MULTI PRODUCTS LINE

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32

EXAMPLE OF LAYOUT CONFIGURATION Robotic Bundler Hight Speed

Robotic Case Packer

Comby Robotic 2 Bundler and 1 Casepacker

Fully integration Robotic Bundler, Case packer & Palletizer Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

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33

EXAMPLE MULTI PRODUCTS FLEXIBLE LINE YOU CAN HAVE DIFFERENT PRODUCTS IN THE SAME BUNDLE/CASE BUNDLER UNIT AND CARTON CASE UNIT CAN WORK SIMULTANEOUSLY DRP

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• • • • • •

4 Delta robot 4 Vision system for inspection 4 Rejection unit for bad product 1 Robotic case packer station 2 Robotic bundler/case station 1 Case station for other type of sku or multi product in the case

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34

DRP

EXAMPLE MULTI PRODUCTS FLEXIBLE LINE YOU CAN HAVE DIFFERENT PRODUCTS IN THE SAME BUNDLE OR CASE

• • • • • •

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4 Delta robot 4 Vision system for inspection 4 Rejection unit for bad product 1 Robotic case packer station 1 Robotic bundler station Double out feed capacity cases and bundling

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35

EXAMPLE OF COMPACT END LINE PALLETIZING STATION FULLY INTEGRATED WITH THE PACKAGING STATION WITH BUDLER AND CASE PACKER

• • • • • •

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4 Delta robot 4 Vision system for inspection 4 Rejection unit for bad product 1 Robotic case packer station 1 Robotic bundler station 3 Robot for palletizing station

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36

CONFIGURATION BUNDLER-CASEPACKER

• • • • •

4 Delta robot 4 Vision system for inspection 4 Rejection unit for bad product 1 Robotic case packer station 1 Robotic bundler station

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37

CONFIGURATION BUNDLER- CASEPACKER & PALLETIZER • • • • • •

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4 Delta robot 4 Vision system for inspection 4 Rejection unit for bad product 1 Robotic bundler station 1 Robotic case packer station 3 Robot for palletizing station

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38

INTRALOGISTIC - FAST TRACK: a solution to de-palletize products and fill cases or trays.

It can be installed at the end of the line or in the warehouse area.

It works according to the modulary concept of DARWIN combining the stations in endless different configurations

Modules & stations for FAST TRACK layout configurations Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

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42

Who knows if there are common sizes & weights for fast delivery for e-commerce?

Common size is 2.000 sq inches or in 1,2 Sq meter Equivalent of dimension of 47x42 Inches or 1x1,2 Meter of pallet size Common a multiple size will be 23 x 17 x 19 Inches or 600x400x500 box size W.D.H Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

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40

PICKING STATION

a robot picks the product from the main line and places it into the case

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41

FAST TRACK MODULES: DEPAL AND CASE ERECTOR

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42

• • • •

16 different products in depal with 12 robots 10 stations of inspection systems for check products the box 10 Station picking station for introduce product in the box 1 Main case erector

PRODUCTS ARE DEPALLETIZED, PLACED IN TRAYS AND THEN IN CARTON CASES BY THE PICKING STATION FOR FAST TRACK AND DELIVERY

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43

PRODUCTS ARE DEPALLETIZED, PLACED IN TRAYS AND THEN IN CARTON CASES

BY THE PICKING STATION FOR FAST TRACK AND DELIVERY • • • •

16 different products in depal with 12 robots 10 stations of inspection systems for check products the box 10 Station picking station for introduce product in the box 1 Main case erector

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44

PRODUCTS ARE DEPALLETIZED, PLACED IN TRAYS AND THEN IN CARTON CASES BY THE PICKING STATION FOR FAST TRACK AND DELIVERY

• • •

24 different products in depal with 12 robots 20 stations of inspection systems for check products the box 20 Station picking station for introduce product in the box

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45

• • •

24 different products in depal with 12 robots 20 stations of inspection systems for check products the box 20 Station picking station for introduce product in the tray

PRODUCTS ARE DEPALLETIZED, PLACED IN TRAYS AND THEN IN CARTON CASES

BY THE PICKING STATION FOR FAST TRACK AND DELIVERY

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46

PRODUCTS ARE DEPALLETIZED, PLACED IN TRAYS AND THEN IN CARTON CASES BY THE PICKING STATION FOR FAST TRACK AND DELIVERY • •

16 different products in depal with 8 robots 10 stations of inspection systems for check products the box

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47

PRODUCTS ARE DEPALLETIZED, PLACED IN TRAYS AND THEN IN CARTON CASES BY THE PICKING STATION FOR FAST TRACK AND DELIVERY • • •

26 different product in depal with 13 robot 20 station of inspection system for check product in the box 13 robot for pick up product in main line put into the box

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48

Thank you for your kind attention

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DARWIN

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50

DARWIN

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51

METERING UNIT STATION

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52

SINGLE ROBOTIC CELL STATION

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53

DOUBLE ROBOTIC CELL STATION

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54

PREFORMING STATION

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55

BUNDLER STATION & MULTILAYER

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56

BUNDLER STATION & MULTILAYER

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57

BUNDLER STATION & MULTILAYER

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58

POLY BAG FORMING STATION – POLARIS

• • • • • •

Unwind Cut Welding Pick & place Vacuum belt table Bag storage

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59

POLY BAG FORMING STATION – POLARIS

• • • • • •

Unwind Cut Welding Pick & place Vacuum belt table Bag storage

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60

PAPER BAG FORMING STATION – POLARIS

• • • • • •

Unwind Cut Welding Pick & place Vacuum belt table Bag storage

Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

61

PALLET US-UK PAPER BAG FORMING STATION – POLARIS

• • • • • •

Unwind Cut Welding Pick & place Vacuum belt table Bag storage

Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

62

CARTON CASE STATION – FROM EMPTY TO FULL CASES

Pallets cases storage – Cases erector Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

63

CARTON CASE STATION – FROM EMPTY TO FULL CASES

Pallets cases storage – Cases erector

Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

64

ANTARES – 13643 comparison

Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

65

ANTARES – 17683 comparison

Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

66

ANTARES – 17890 comparison

Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

67

ANTARES – 18359 comparison

Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

68

ANTARES – 18359 comparison

Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

69

PALLET US-UK

Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

70

PALLET US-UK

Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

71

PALLET US-UK

Le informazioni qui riportate sono di proprietà di Pulsar Engineering Srl che ne vieta la copia e la diffusione senza specifica autorizzazione The information contained herein are property of Pulsar Engineering Srl which prohibits copying and distribution without specific authorization

72