SUCCESS STORIES - Zerhusen
Demand-oriented transport securing in the corrugated board industry
Equipped with machines from Mosca GmbH , Zerhusen straps and wraps its corrugated board products automatically - and can concentrate fully on production thanks to consistent processes.
From paper pulp to stable, precisely fitting packaging or continuous material: at Zerhusen 's new plant, employees process the raw material produced at the main plant in Damme into corrugated cardboard products in a wide variety of formats. The product range extends from folding boxes and erecting boxes to die-cut and heavy goods packaging, with Zerhusen operating various production lines in the new plant and also producing customized products on customer request. Every day, around 120 trucks with a wide variety of palletized corrugated cardboard products leave the plant and make their way to customers. However, the goods must first be secured for transportation - and each product has its own requirements.
An additional challenge: strict hygiene requirements apply in the food sector in particular and the corrugated board products used there must not be exposed to any contamination during transportation. Goods intended for the retail trade must also not come into contact with moisture or dust in order to present the products placed in them in the best possible light. Both product groups therefore require additional protection during transportation from the production facility to the end customer.
Combination of strapping and wrapping
Strapping is an efficient standard solution for the safe transportation of corrugated cardboard products in particular. Additional wrapping of the pallet also makes it possible to reliably protect the products from dust and moisture and to additionally stabilize them during transport. Material consumption can also be significantly reduced, particularly in combination with prior strapping.
In order to meet the requirements of their products and customers, Zerhusen turned to Mosca - and together the companies developed a flexible End-of-Line that enables strapping and wrapping as required. "We have benefited greatly from sourcing both packaging solutions from a single source," says Bolles.
Protection from dust and moisture
Thanks to variable film tension and pre-stretching, the winder avoids wasting resources as well as film tears. The pre-stretching can be infinitely adjusted up to 400 percent.
The wrapper automatically applies the film to the pallet by rotating the ring around the static pallet. The film carriage is raised and lowered so that the pallet is wrapped evenly. This prevents any shearing points that could make the loading unit unstable. Counter plate sealing ensures high-bay-safe packaging.
The final configuration
The final configuration consists of a combination of the KCK-131 pallet strapping machine from Mosca and a Saturn S6 Stretch Wrapping Machines from Mosca Movitec. Both machines are connected by conveyor elements, which take over the alignment and transportation of the loaded pallets.
Edge protector feeder
The pallet strapping machine is characterized, among other things, by an upper edge protection feeder that places corrugated cardboard sheets on the packaged goods to protect the product edges.
Lifting turnstile
A lifting turnstile is also part of the equipment: employees can use it to automatically turn the loaded pallets 90° in the direction of travel after strapping in order to strap them crosswise a second time
Satisfied customer
The KCK-131 pallet strapping machine and theSaturn S6 Stretch Wrapping Machines guarantee secure loads and transport routes at Zerhusen.
"We work with different load carriers and numerous special pallets with individual customer requirements. It must therefore be possible to flexibly adapt the transport securing to the different products and load carriers," explains Jan Bolles, final packaging foreman at Zerhusen. "Thanks to Mosca 's flexible strapping solutions, we can ensure that our goods reach their destination safely on all load carriers."
Mosca 's project technicians set everything up and put it into operation in just four days; the process then ran smoothly right from the start. This continues to this day and makes our work much easier