Completing phase 2 of our canning line upgrade
The final section of the canning line upgrade on our largest canning line has just been completed. In November we completed phase 1 which included the installation of a Westrock cluster wrap machine. This machine wraps cans in 4, 6 or 10 packs cardboard wrap. Read more about phase 1 here. Phase 2 incorporated a Fibre King machine that wraps the outer carton (16, 24 or 30 pack) around the cluster paks and then stacks them onto a pallet ready for transport.
Arriving in 6 pieces, across 2 shipping containers from Thailand, our Maintenance team removed all items from the containers to begin the installation and commissioning of the upgrade alongside the Fibre King team. Built in one week, and commissioned in the next, we are beyond thrilled to begin 2023 with optimised equipment. This upgrade will enable IDL to operate the canning line at it’s maximum speed of 10,000 cans per hour, every hour.
Capable of canning wine, cider, rtd’s and non-alc products across a variety of sizes, canning line #2 is expected to package millions of cans this year. In only a few short months we have upgraded the canning line, made its operation more efficient, decreased the use of paktech handles, and worked with our suppliers and customers to update all artwork for wraps and outer cartons to match new dielines.
Carton wrapping
Depending on the elected pack size, wrapped cans are shifted into a pattern before being slid into an open carton, which is then sealed shut. The new conveyors lead 4, 6 or 10 pack can clusters into the Fibre King machine ready to be loaded into a carton. 4 pack clusters can be loaded into a 16 or 24 can slabs and 10 pack cans are loaded into a 30 pack outer carton.
Pallet stacking
The final portion of our canning line is a compact modular palletiser from Fibre King. This machine utilises compressed air and a robotic arm to pick up full slabs from the carton wrap machine, and stack full cartons in a pattern on a pallet. When packaging 16 can slabs, the modular palletiser picks up two full slabs at a time and stacks onto the pallet. When packaging 24 or 30 can slabs, the modular palletiser picks up one full slab at a time and stacks into a pattern on a pallet.
Increased speed
Previously, a full pallet was generated roughly every 30 minutes and during commissioning, full pallets were packaged every 16-20 minutes. Once fully commissioned, we expect this speed to increase further. We anticipate that with this machine upgrade finalized we will be capable of operating this canning line at 10,000 cans per hour consistently as the filler, seamer, cluster wrap, carton wrap and palletiser can all keep up with this speed.
Enhanced electrical sensor communication
Each of our packaging lines are fitted with state-of-the-art electrical sensor communications. This allows different sections of our packaging lines to speed up or slow down in order to ensure consistent operation of our packaging lines.
A special mention to our team of trades who worked together to complete this project
· IDL Maintenance Manager Wally
· IDL Maintenance Fitters Andrew & Brant
· LGE Electrical
· Fibre King