Robotized systems to increase the Smart Factory sustainability

BEMA LAB, the laboratory devoted to the growth and sharing of technical experience

Bema Lab represents the perfect synthesis between cutting-edge industrial reality and corporate values of sustainable growth. An in-house research and consultancy team tests wrapping and labeling recipes with the aim of developing the best tertiary packaging solutions for its customers, ensuring maximum load stability, total traceability and product integrity, as well as a significant reduction in the packing material used.
Two systems check the load stability at different speeds and on different means of transport: the vibrating table for the simulation of transport by road, sea or rail and the bench for pallet acceleration and stability test complying with standard EUMOS 40509, which is a recognized standard applicable under European directive EU 2014/47 for load safety on the road. In addition, a set of load cells is used to measure the containment force of the film on the product’s corners during the wrapping process. Therefore, inside Bema Lab we test the stability of the various products and we develop a custom wrapping solution, guaranteeing results to the customer over time.

Credits: Kai-Uwe Schulte-Bunert

SILKWORM, an innovative and sustainable robotic wrapping solution

Flexibility, redundancy, high speed, reduced use of film, operational autonomy for a compact layout: these are the fundamental characteristics of Silkworm, the system that has revolutionized the concept of stretch film wrapping by combining robotics with the use of a 1000-mm high film reel and the product in rotation which ensure the system fast speed.

The automatic wrapping head changeover allows to increase in total safety the plant efficiency compared to the standards: a patented technology that, thanks to the two heads, guarantees operational continuity and 8-hour autonomy with a single system.

The use of the 1000-mm high and 60-kg film reel considerably reduces the replacement frequency, enabling to lower, compared to traditional systems that employ 500-mm reel, the number of wrapping turns.

The management software combined with the 1000-mm reel allows to create the wrapping recipe suited to every customer’s requirements, controlling the film pre-stretch value and using only the quantity of film required according to the type of product. Therefore, Silkworm guarantees maximum load stability, dramatic reduction in the quantity of film used, in energy consumption and maintenance costs.

FILM DOUBLING, an absolute novelty in the field of wrapping techniques

To ensure a further increase in plant sustainability, we have developed, inside the Bema Lab, the Film Doubling technology.
This study aims to improve the distribution of the wrapping film on the palletized goods, maximizing it in the points deemed more critical - such as, for example, the first product layer -and at the same time reducing it in the points where it is not necessary: with the conventional wrapping techniques, in fact, the greatest amount of film concentrates in the central part of the pallet.
This patented device, incorporated in the wrapping head, enables to obtain, at a given moment in the wrapping cycle, two separate bands of film that will be overlapped before being applied to the pallet. In the first part of the wrapping cycle, the band of film is wholly applied, while in the second part of the cycle, the band of film is doubled. This innovative technique guarantees a stronger anchorage between pallet and first layer of product, preventing its misalignment.  Compared to traditional systems, the Film Doubling allows to have the same load stability with a considerable plastic film saving, as experienced by our customers.

RAPTOR, a labeling solution that increases flexibility and speed

Raptor, the robotic labeling redundant system, is fitted with an anthropomorphic robot which enables the automated application of labels on more sides and more levels, guaranteeing flexibility and operational high speed in reduced spaces. The applicator arm is equipped with a camera to check the label correct application and the barcode readability. The system redundancy, thanks to the option with two printers, allows to double the operational autonomy and to carry out the label reel automatic changeover without any production stoppage, thus increasing the overall end-of-line efficiency.
The robotic labeler presents an optimal ergonomics for the operator that replaces the reel outside the perimeter guards, in total safety, without interrupting the labeling cycle.

ROBOTIC SYSTEMS from E80 Group on Vimeo.