Automatic Palletising Systems

AUTOMATIC PALLETISING SYSTEMS

Y EA R 3 S APS SERIES

Automatic palletizing systems

SMI palletizing systems set a new standard in the scenario of robotized palletizers equipped with two Cartesian axes. SMI's APS series is the result of intense research and innovation, which has allowed us to implement technologically advanced systems that now offer each user the packaging solution best suited to his/her needs. SMI palletizing systems are able to optimize the end-of-line operations of many industrial sectors: beverage production, agricultural and food, chemicals, pharmaceuticals, detergents, glass, paper and many others. The APS series consists of automatic systems that palletize cardboard blanks, packets, trays, and packs in general. By integrating the central column of all the system's main functions, SMI's palletizing systems are extremely compact and easily adaptable to any logistic condition of the line end area, both in existing systems and in new installations.

2 SMI palletizing systems are able to optimize the end-of-line operations of many industrial sectors: beverage production, agricultural Low transportation costs and food, chemicals, pharmaceuticals, detergents, glass, paper and many others. The single-column module fits easily inside a standard 20' container, which reduces transportation and storage costs Fast and accurate operations Maximum safety at all times and simplifies shipping paperwork. Each module is assembled, pre-wired and tested before delivery, which simplifies and APS series palletizers are equipped with independent The range of SMI's APS quickens assembly and start-up at the customer's facility. machine axes driven by electronically-controlled brushless series palletizers is motors, which ensure fast, smooth and accurate equipped with a brand movements. new dedicated “Safety The use of this solution in the field of palletizing systems, PLC”, which allows you to characterized by repetitive actions, is a guarantee to program the safety systems achieve high reliability, reduce maintenance and ensure in a flexible, reliable and low running costs. efficient manner. The PLC monitors the Innovative technology and ease of use proper operation of all the machine's safety devices, integrating them together. Both automation and control on-board the machine rely on It also allows the user to create custom protection areas within innovative technology based on Sercos fieldbus, through which the perimeter of the palletizing system. the operator can quickly and easily manage all palletizing This significantly reduces machine downtime both in case of operations at the end of the line using a simple and user- emergencies and when loading pallets, interlayer pads, etc., friendly man-machine interface. thanks to differentiated logics for the various areas of intervention. System management is made even easier by the use of As such, maintenance is easier and any adjustment to future advanced graphics, touch screens and a wide range of safety standards will be faster and safer as they will be diagnostics and technical support available in real time. upgraded directly via the PLC's program. FEATURES SPEED* The system's high degree of automation features low energy 35 PPM BASIC OPERATIONS costs as well as low running and maintenance costs. Energy savings and reduced maintenance APS 1035 100 LPH SMI's APS palletizing systems easily fit into existing or newly BASIC OPERATIONS 35 PPM Guaranteed strength and reliability APS 1035 P installed packaging lines and are immediately operational. INTERLAYER PADS INSERTER 100 LPH The accurate sizing of both By integrating multiple functions into just a few operating APS 1550 P 3-IN-1 FUNCTIONAL UNIT 50 PPM the column and the horizontal units, these systems are assembled, pre-wired and SCARA TECHNOLOGY 200 LPH beam, combined with their tested at the factory before delivery, hence minimizing ERGON sliding on recirculating ball assembly and start-up at the customer's facility. APS 3090 P 3-IN-1 FUNCTIONAL UNIT 90 PPM runners, ensure fluid and The system's high degree of automation, its mechanical ERGON SCARA TECHNOLOGY 300 LPH continuous movements with simplicity, the use of robot-based components and minimal dynamic buckling MANIPULATOR-EQUIPPED its structural optimization allow a significant cut in APS 3100 LP IN-LINE PRE-COMPOSITION 100 PPM and virtually no vibrations: this maintenance costs and reduction in energy consumption, ERGON 3-IN-1 FUNCTIONAL UNIT 300 LPH is the key to ensuring a long as well as the extension of the system's life cycle. SCARA TECHNOLOGY lifecycle of the mechanical components. *Max speed refers to pattern layer 21, 3x2 packs, 1.5 L bottles. (PPM: packs per minute - LPH: layers per hour)

3 APS 1035 SERIES

UP TO 35 PPM*

Fixed column with gripper The APS 1035 is made up of a single- column palletizing system with two Cartesian axes, with bottom-up movements. The vertical axis consists of a fixed column on which the horizontal beam slides on recirculating ball guides; the gripper slides horizontally on said beam, always on recirculating ball guides. The gripper picks up the rows of packs Grouping of packets and row/layer pre-composition Composing the layer on the pallet from a conveyor belt at operator height Packs arriving on the single-lane infeed belt are grouped in the The gripper picks up the row of packs from the conveyor belt and places them on the pallet by means row pre-composition area and queued in one line, facing the same (located at operator height) and places it on the pallet in the specific of fast and accurate movements. direction (all are fed either on the long side or on the short side), point by means of fast and accurate movements. The beam's vertical movements and the therefore creating the palletizing row that, formed in this manner, is The beam's vertical movements and the gripper-holder's horizontal horizontal ones of the gripper-holder are taken from the gripper and placed on the pallet. movements are driven by brushless motors, which ensure perfect driven by brushless motors, which ensure If required by the palletizing pattern, a turntable rotates the pallet trajectories during all palletizing phases. perfect trajectories during all palletizing by 90° to change the row's direction. phases.

*Max speed refers to pattern layer 21, 3x2 packs, 1.5 L bottles. (PPM: packs per minute - LPH: layers per hour) 4 Standard configuration

All the modules featuring the APS palletizing systems are Pallet magazine Pad and pad-inserter magazine designed according to FCR (Full Cost Reduction) methodologies and supplied to the customer fully assembled and wired. Adjustable fork This pad magazine can magazine for empty be adjusted according pallets featuring the: to the various sizes of Single-row entry with simple pre-composition 1) loading of the pallets the interlayer pads. into the magazine in This pad-inserter unit This single-entry both directions; with controlled axes layer-composition (brushless) is made system is equipped 2) releasing of the up of a fixed column with a double rubber- pallet to the line, equipped with a coated cadencing both from the front translating arm that belt and a product and from the side (on lifts vertically. insertion belt the task the right and the left) of which is to form for extreme layout Suction cups grasping system through from 4 to 8 adjustable points the row/layer. flexibility. to ensure the proper lifting of any type of interlayer pad. It is normally combined with a longer roller or chain conveyor (depending on the pallet's loading and releasing direction). Fixed column with gripper Storage capacity: 12 pallets of standard height (europallet = 144 This single column mm). has two Cartesian axes, along which the Pallet roller conveyor horizontal beam slides This is a galvanized up and down on ball steel structure with ø recirculation guides. 76-mm rollers and 150- The gripper slides mm pitch, motor driven horizontally on said by a 5/8" chain. beam, also on ball Electronically reversible recirculation guides. central motorization. The gripper picks up the row of packs from a conveyor belt at Available in different operator height and places it, by means of fast and accurate lengths: 1500 mm, movements, onto the pallet in the specific point. 2000 mm, 2500 mm The vertical and horizontal movements are driven by brushless and 3000 mm. motors, which ensure perfect trajectories during all palletizing phases.

5 APS 1550 P SERIES

UP TO 50 PPM*

"3-in-1" fixed column equipped with SCARA technology loading head and arm This system combines the palletizing operations, the feeding of the empty pallets and the insertion of the interlayer pads inside the structure of the “3-in- 1” central column: i.e. three processes side of the column that remains clear when the packs are inserted High operational reliability and compact size usually carried out by separate machines into the loading head is exploited by the system for housing the within their own dedicated spaces. mechanical assembly fitted with SCARA technology, which manages The operations of the SCARA arm are handled by the machine's The integration of these three functions pallet flow and interlayer pad insertion. automation and control system in perfect synch with the operations inside the central column is made possible This assembly essentially consists of an articulated horizontal arm performed by the layer-loading head, so that the vertical and horizontal by a series of technical innovations that mounts, at its far end, both a gripper to pick up the pallets and movements of the various mechanical units moving on the central devised by SMI design engineers. a suction cup-grasping unit to move the cardboard interlayer pads. column can follow precise and coordinated trajectories that prevent Specifically, the horizontal beam on The arm slides up and down in the central column in order to pick any contact or interference between one another. which the layer loading head slides is up and release the pallets and interlayer pads, and then it slides SMI's APS automatic palletizing system offers all the advantages equipped with a telescopic guide system horizontally to transfer the pallets and interlayers from their of Cartesian axes technology but with reduced machine overall that allows the beam to move faster on magazines to the palletizing pallet. dimensions as compared to traditional solutions. its own transverse axis. In this way, the

*Max speed refers to pattern layer 21, 3x2 packs, 1.5 L bottles. (PPM: packs per minute - LPH: layers per hour) 6 Standard configuration

Grouping of packets and row/layer pre-composition All the modules featuring the APS palletizing systems are arm integrates the functions related to the feeding of the empty designed according to FCR (Full Cost Reduction) methodologies pallets and the insertion of the interlayer pads. The infeed section is equipped with a layer pre-composition and supplied to the customer fully assembled and wired. system consisting of mat belt system. As an accessory you Empty pallets feeding system can add a pack-turning device based upon a “pack-hindering” system or, alternatively, a newly designed gripper-equipped The APS palletizer is Single infeed manipulator; this latter device gets the packs in transit rotated equipped with a system when requested by the palletization pattern, without being This single-infeed layer that feeds the empty affected by the mishaps related to “pack-hindering” type pack- composition system pallets, and is made turning units. Through these systems, the packs are rotated comes with a rubber- up of roller or chain before the row is formed. coated cadencing belt, conveyors (depending on a product-insertion belt the pallet's loading and the task of which is to releasing direction). form the row, and a one- Storage capacity: about way translation system 10 pallets for a total max that contributes to the height of 1700 mm. formation of the layer. Interlayer pad feeding system The layer is transferred from the belt to the basket smoothly and precisely as it exploits the belt's movement, and does not require Pad feeding system the use of any mechanical layer translation components. adjusted according to different interlayer pad sizes. "3-in-1" fixed column equipped with This controlled-axes SCARA technology loading head and arm pad-inserting unit The "3-in-1" fixed column (depending on the Composing the layer on the pallet houses the mechanical chosen palletizing parts designed to carry system) is built into This stage of the palletizing process composes a row of packs out the palletizing the central column of which is later moved, by means of a loose bar, onto a layer- operations, feed the the APS palletizer. Suction cup-grasping system with 4 to 8 composing “parking” belt, awaiting the subsequent rows. empty pallets and insert adjustable points, to ensure the proper lifting of any type of From here, a conveyor belt gently introduces the complete the interlayer pads, i.e. interlayer pad. layer into the loading head, the so-called “basket”, which three processes usually finally transfers it to the pallet being formed. carried out by separate Pallet roller conveyor This configuration allows the arranging of almost 4 layers machines within their own dedicated spaces. in sequence and within a very limited space (one partially This is a galvanized steel structure with ø 76-mm rollers and 150-mm formed, one “parked”, one on the loading head and the last The horizontal beam on which the layer loading head slides is pitch, motor driven by a 5/8" chain. one on the pallet), thus ensuring greater system efficiency. equipped with a telescopic guide system that allows the beam to Electronically reversible central motorization. Available in different move faster on its own transverse axis while the SCARA articulated lengths: 1500 mm, 2000 mm, 2500 mm and 3000 mm.

7 APS 3090 P SERIES

UP TO 90 PPM*

*Max speed refers to pattern layer 21, 3x2 packs, 1.5 L bottles. (PPM: packs per minute - LPH: layers per hour) 8 Standard configuration

Grouping of packets and row/layer pre-composition All the modules featuring the APS palletizing systems are arm integrates the functions related to the feeding of the empty designed according to FCR (Full Cost Reduction) methodologies pallets and the insertion of the interlayer pads. The infeed section is equipped with a layer pre-composition and supplied to the customer fully assembled and wired. system consisting of mat belt system. As an accessory you Empty pallets feeding system can add a pack-turning device based upon a “pack-hindering” system or, alternatively, a newly designed gripper-equipped The APS palletizer is Double infeed manipulator; this latter device gets the packs in transit equipped with a system rotated when requested by the palletization pattern, without This double-infeed layer that feeds the empty being affected by the mishaps related to “pack-hindering” composition system pallets, and is made type pack-turning units. comes with two rubber- up of roller or chain Through these systems, the packs are rotated before the coated cadencing belts, conveyors (depending row is formed. two product-insertion on the pallet's loading belts the task of which and releasing direction). is to form the row and Storage capacity: about a one-way translation 10 pallets for a total system that contributes max height of 1700 mm. to the formation of the layer. The layer is transferred from the belt to the basket smoothly Interlayer pad feeding system and precisely as it exploits the belt's movement, and does not Pad feeding system require the use of any mechanical layer translation components. adjusted according to different interlayer pad sizes. "3-in-1" fixed column equipped with This controlled-axes SCARA technology loading head and arm pad-inserting unit The "3-in-1" fixed column (depending on the Composing the layer on the pallet houses the mechanical chosen palletizing parts designed to carry system) is built into This stage of the palletizing process composes a row of packs out the palletizing the central column of which is later moved, by means of a loose bar, onto a layer- operations, feed the the APS palletizer. Suction cup-grasping system with 4 to 8 composing “parking” belt, awaiting the subsequent rows. empty pallets and insert adjustable points, to ensure the proper lifting of any type of From here, a conveyor belt gently introduces the complete the interlayer pads, i.e. interlayer pad. layer into the loading head, the so-called “basket”, which three processes usually finally transfers it to the pallet being formed. carried out by separate Pallet roller conveyor This configuration allows the arranging of almost 4 layers machines within their own dedicated spaces. in sequence and within a very limited space (one partially This is a galvanized steel structure with ø 76-mm rollers and 150-mm The horizontal beam on which the layer loading head slides is formed, one “parked”, one on the loading head and the last pitch, motor driven by a 5/8" chain. equipped with a telescopic guide system that allows the beam to one on the pallet), thus ensuring greater system efficiency. Electronically reversible central motorization. Available in different move faster on its own transverse axis while the SCARA articulated lengths: 1500 mm, 2000 mm, 2500 mm and 3000 mm.

9 APS 3100 LP SERIES

UP TO 100 PPM*

"3-in-1" fixed column equipped with SCARA technology loading head and arm This system combines the palletizing operations, the feeding of the empty pallets and the insertion of the interlayer pads inside the structure of the “3-in-1” central column: i.e. three processes usually carried out by separate machines within their own dedicated spaces. loading head is exploited by the system for housing the mechanical The integration of these three functions inside High operational reliability and compact size assembly fitted with SCARA technology, which manages pallet flow the central column is made possible by a series and interlayer pad insertion. The operations of the SCARA arm are handled by the machine's of technical innovations devised by SMI design This assembly essentially consists of an articulated horizontal arm automation and control system in perfect synch with the operations engineers. that mounts, at its far end, both a gripper to pick up the pallets and performed by the layer-loading head, so that the vertical and horizontal Specifically, the horizontal beam on which the a suction cup-grasping unit to move the cardboard interlayer pads. movements of the various mechanical units moving on the central layer loading head slides is equipped with a The arm slides up and down in the central column in order to pick column can follow precise and coordinated trajectories that prevent telescopic guide system that allows the beam up and release the pallets and interlayer pads, and then it slides any contact or interference between one another. to move faster on its own transverse axis. In horizontally to transfer the pallets and interlayers from their SMI's APS automatic palletizing system offers all the advantages this way, the side of the column that remains magazines to the palletizing pallet. of Cartesian axes technology but with reduced machine overall clear when the packs are inserted into the dimensions as compared to traditional solutions.

*Max speed refers to pattern layer 21, 3x2 packs, 1.5 L bottles. (PPM: packs per minute - LPH: layers per hour) 10 Standard configuration

Grouping of packets and row/layer pre-composition All the modules featuring the APS palletizing systems are designed machines within their own dedicated spaces. The horizontal beam on according to FCR (Full Cost Reduction) methodologies, tested which the layer loading head slides is equipped with a telescopic guide This model is and supplied to the customer fully assembled and wired. system that allows the beam to move faster on its own transverse axis equipped with a while the SCARA articulated arm integrates the functions related to the continuous, in-line Entry with continuous pre-composition feeding of the empty pallets and the insertion of the interlayer pads. layer precomposition Continuous layer system. By means Empty pallets feeding system of an innovative unit composition system: by of gripper-equipped means of an innovative The APS palletizer is manipulators the unit of gripper equipped equipped with a system loose packets flowing manipulators the loose that feeds the empty on the infeed belt are packs flowing on the pallets, and is made up of turned and/or translated and set on multiple lanes according to infeed belt are turned roller or chain conveyors the palletizing pattern, hence pre-composing the layer. A specific and/or translated (depending on the pallet's mechanical actuator separates the newly completed layer from and set on multiple loading and releasing the accumulating loose packets while the manipulator system lanes according to direction).Storage capacity: prepares the next layer. the palletizing pattern, hence pre-composing the layer. A specific about 10 pallets for a total mechanical actuator separates the newly completed layer from the max height of 1700 mm. Composing the layer on the pallet accumulating loose packets while the manipulator system prepares the next layer. The layer, composed in this manner, is inserted into Interlayer pad feeding system The layer of packs the basket smoothly and precisely as it exploits the belt's movement, arriving from the Pad feeding system and does not require the use of any mechanical layer translation mechanical separating adjusted according to components. The entry with continuous pre-composition is very actuator is inserted different interlayer pad compact and allows the optimizing of space at the end of the line. into the loading head sizes. This controlled- This system differs from the traditional ones due to its one-way (basket) smoothly axes pad-inserting motion and to the possibility of orienting the packets in any position. and precisely as it unit (depending on exploits the belt's the chosen palletizing "3-in-1" fixed column equipped with movement, and does system) is built into the SCARA technology loading head and arm not require the use of central column of the any mechanical layer translation components. The "3-in-1" fixed column APS palletizer. Suction The entry with continuous pre-composition is very compact and houses the mechanical cup-grasping system with 4 to 8 adjustable points, to ensure the allows the optimizing of space at the end of the line. parts designed to carry proper lifting of any type of interlayer pad. This system stands out from traditional ones due to its one- out the palletizing way motion and to the possibility of orienting the packets in operations, feed the Pallet roller conveyor any position. empty pallets and insert This is a galvanized steel structure with ø 76-mm rollers and 150-mm the interlayer pads, i.e. pitch, motor driven by a 5/8" chain. Electronically reversible central three processes usually motorization. Available in different lengths: 1500 mm, 2000 mm, carried out by separate 2500 mm and 3000 mm.

11 APS SERIES

Accessory devices

Pallet chain conveyor Pallet rotation Magnetic head • Galvanized steel • Galvanized steel structure. Device for the replacement of the standard basket in case the structure for pallet • Roller- or chain-fitted system palletizing operations require it and only for palletizing products handling by means of for the rotation of the whose upper part is made of iron (for example tinplate cans and chains, ¾" pitch, for pallets while maintaining the glass jars with iron cap). optimal transfer in the advancing front. The magnetic head can also be equipped with another accessory non-rolling direction. • Electronically reversible cen- enabling its rotation. tral motorization. • Electronically reversible The system is delivered to the customer fully assembled and central motorization. wired. • Available in three different lengths: 1500 mm, 2000 mm and This accessory is operated by the electrical panel of the APS 3000 mm. palletizing system's central module. The system is delivered to the customer fully assembled and wired. This accessory is operated by the electrical panel of the Pack rotation by manipulator system central module of the APS palletizing system. This optional pack-rotating device is made up of an innovative newly-designed gripper-equipped manipulator that gets the pack in transit rotated and sets it in the required position. This option Translating pallets on rollers/chains at 90° allows to reduce mishaps related to “pack-hindering” type pack- • Galvanized steel turning units. structure. • Mixed system of rollers and chains for the orthogonal deviation of the pallets with reversal of the advancing front.

• Electronically reversible central motorization. The system is tested at Smipal and delivered to the customer fully assembled and wired. This accessory is operated by the electrical panel of the central module of the APS palletizing system.

12 Packposer Packsorter Automation

SMI only manufactures The automation and control system of SMI machines, The Packposer divider-laner receives The Packsorter divider-laner receives advanced technology palletizers, called MotorNet System®, includes the following the packs coming from the packer the packs in single lane coming from featuring modular design, hardware components: MARTS (process controller), positioned upstream and, by means the packer positioned upstream and, operating flexibility and high POSYC (man-machine interface), COSMOS (digital of an innovative manipulation system by means of an innovative manipulation energy efficiency, thanks to servodriver for brushless motors), dGATE and aGATE based on three Cartesian axes (x, y system based on three Cartesian axes fully automatic processes, (remote IP65 I/O digital/analogic modules). and z) and equipped with a motorized (x, y and z), arranges them on two or electronically controlled drive gripper, turns them and/or arranges more lanes and conveys them toward shafts and field bus wiring. The MARTS is a PAC (Programmable Automation them on two or more lanes, thus the automatic palletisation system Controller), based on an industrial PC, which can composing the format of repackaging positioned downstream. The hardware and software be programmed in IEC61131 languages. The COSMOS set by the packaging machine's work components are “open“ and servodrivers and the dGATE/aGATE I/O modules are program positioned downstream. The divider can receive also packs in modular, in compliance with the connected to the PAC via sercos. The divider is made of top-quality double lane, thus working simply as a most important international certifications and rely materials, ensuring operating reliability conveyor toward the palletizer. upon consolidated standards of the industrial field The POSYC is a HMI terminal, (touch screen IP65), and long-term duration. The use of based on an industrial PC with solid state drives. The divider is made of top-quality and of the packaging sector: OMAC guidelines (Open wear-resistant components minimizes Modular Architecture Controls), sercos, PROFIBUS, the maintenance and cleaning materials, ensuring operating reliability IEC61131, OPC, Industrial PC. operations, thus reducing the total and long-term duration. operating costs. The use of wear-resistant components In particular, by following the OMAC guidelines and minimizes the maintenance and the Omac Packaging Workgroup (OPW), SMI can cleaning operations, thus reducing the guarantee easy integration with the other machines total operating costs. in line, user friendly technology and maintenance of the investment value.

Moreover, SMI systems are compliant with the technical requirements of Industry 4.0 and IoT (Internet of Things) technologies, which allow to easily and effectively run production lines within a “Smart Factory”, even remotely through mobile devices.

13 www.smigroup.it

SMI S.p.A. Y EA Via Carlo Ceresa, 10 R I-24015 San Giovanni Bianco (BG) S Tel.: +39 0345 40.111 Fax: +39 0345 40.209 3

E-mail: [email protected] DP010319