Read on to discover how this solution improved efficiency and space utilization.
OBJETIVE
Our customer, a leading manufacturer of household products, aimed to increase production line autonomy to improve efficiency and reduce manual intervention. Their existing unscrambling solution was unreliable, causing downtime and disrupting workflow. They sought a solution that would allow operators to load bottles into a large storage system before production began, freeing them to focus on higher-value tasks while ensuring continuous line operation.
CHALLENGES
The customer faced a key challenge: limited shop floor space. Expanding production equipment risked compromising operational flow and forklift access. Any solution had to maximize space efficiency without sacrificing productivity.
POSIMAT’S SOLUTION
POSIMAT engineered a compact, high-efficiency bottle-handling system tailored to the customer’s space constraints and production goals.
• Vertical integration: We designed an integrated 6,000-liter silo positioned above the unscrambler, maximizing vertical space and freeing up valuable floor space.
• Seamless automation: Bottles are fed into a small hopper with a minimal footprint, transported via conveyor from the storage room.
• Smart, sensor-controlled operation: The system automatically elevates bottles into the silo, which supplies bottles to the unscrambler on demand — ensuring uninterrupted production.
• Gentle handling: The system’s soft handling mechanism preserves bottle integrity, ensuring consistent bottle quality.
• Operator efficiency: Reduced manual intervention allows operators to focus on other critical tasks, improving overall workflow.
• Vertical integration: We designed an integrated 6,000-liter silo positioned above the unscrambler, maximizing vertical space and freeing up valuable floor space.
• Seamless automation: Bottles are fed into a small hopper with a minimal footprint, transported via conveyor from the storage room.
• Smart, sensor-controlled operation: The system automatically elevates bottles into the silo, which supplies bottles to the unscrambler on demand — ensuring uninterrupted production.
• Gentle handling: The system’s soft handling mechanism preserves bottle integrity, ensuring consistent bottle quality.
• Operator efficiency: Reduced manual intervention allows operators to focus on other critical tasks, improving overall workflow.
RESULTS AND IMPACT
POSIMAT’s smart, space-saving solution delivered measurable benefits:
• Increased production line autonomy: High accuracy and repeatability at every stage, with quick and easy changeovers saving valuable production time.
• Optimized floor space usage: Consistent jar handling minimizes jams and rejections, ensuring a steady downstream supply.
• Consistent product quality: Lower maintenance requirements, fewer part replacements, and higher operational efficiency led to significant annual savings in labor and production costs.
• Increased production line autonomy: High accuracy and repeatability at every stage, with quick and easy changeovers saving valuable production time.
• Optimized floor space usage: Consistent jar handling minimizes jams and rejections, ensuring a steady downstream supply.
• Consistent product quality: Lower maintenance requirements, fewer part replacements, and higher operational efficiency led to significant annual savings in labor and production costs.
CONCLUSION
This project showcases POSIMAT’s ability to design and implement intelligent, space-saving solutions that enhance production efficiency.