Sinit Kunststoffwerke GmbH, based in Rödental near Coburg, are experts in plastic parts and assemblies made from thermoplastics. High-quality plastic components for the electrical and food industries are produced at the Bad Schwalbach site near Wiesbaden. Sinit has been consistently focusing on automation for years and has an automated guided vehicle system (AGV) from EK Robotics in operation there with three transport robots from the Vario Move series for the intralogistical flow of goods.

The AGV is already the second system from EK Robotics with which Sinit has taken its internal transport logistics processes to the next level. Production in Bad Schwalbach with 29 injection molding machines is highly automated. Individual parts and entire assemblies are produced from plastic granulate, precisely according to the wishes of international customers. Customized answers and tailor-made solutions are the strengths of this medium-sized family business with over 260 employees at five locations in Europe. The Sinit plant in Bad Schwalbach employs 80 highly qualified specialists, who also manufacture the necessary molds and injection molding tools themselves.

Until 2020, the finished products were simply placed by hand wherever there was space until they were needed for further assembly or prepared for shipping. This is not a sustainable situation for Sinit, explains Thomas Wisser, Managing Director of Sinit: "Transporting goods in-house by hand costs too much time and money. If you look at what is possible today in the age of Industry 4.0, there is no alternative to an automated guided vehicle system like the one from EK Robotics."

Convincing solution, infinite variety

To get an impression of the endless possibilities of EK Robotics' transport solutions, Sinit only needed to look at its own company headquarters in Rödental near Coburg. An AGV with three transport platforms from the Fast Move series has been in use here since 2019. "The experience with the system in Rödental and the appealing concept for the new Vario Move series tipped the scales in favor of putting an AGV from EK Robotics into operation in Bad Schwalbach as well," says Thomas Wisser. "The system was to form the link between our fully automated production systems and the previously inefficient conveyor technology in the logistics and assembly areas."

One of Sinit's main requirements was to ensure the unrestricted availability of the transport robots in Bad Schwalbach, 24 hours a day, seven days a week. An initial transport concept was developed for this purpose, initially with a small number of transfer points. This was gradually increased in the course of implementation and constantly adapted to the circumstances. Throughout the entire project phase, prompt support from the specialists at EK Robotics was guaranteed at all times, recalls Thomas Wisser. Quick and sustainable solutions were also found for complex situations and implemented immediately. "With each additional vehicle that went into operation in Bad Schwalbach, the learning curve increased on both sides," he summarizes. "In this way, we were able to completely resolve the teething troubles to be expected with such a new system over the course of the project." Today, the Vario-Move system proves its qualities in operation at Sinit every day anew, not least thanks to its ease of operation.

Flexible charging concept

"The project at Sinit is one of our first with the Vario Move series, which fulfills a wide range of transport requirements with its modular concept," adds Ronald Kretschmer, Chief Sales Officer (CSO) at EK Robotics. "Vario Move defines the new, industrial-grade benchmark in its class. Compared to other transport robots, Vario Move achieves a significantly longer life cycle thanks to its very robust and high-quality design."

With a load capacity of up to 1.6 tons, safe load transfer at heights of up to 5 metres and a travel speed of up to 2 m/sec, the transport robots in the Vario Move series offer outstanding performance. The smart quick-charging system also ensures uninterrupted operation, as the high-level vehicles virtually decide for themselves when to drive to their charging station. If a vehicle does not currently have a job and the battery charge level is below a predefined threshold, it drives directly to the charging station and docks there. If the battery is sufficiently charged, the AGV moves to its waiting position or rolls off as soon as it is needed and has received a new order. The time at the charging station is not fixed; instead, the vehicles adapt variably to the current conditions.

Best results in the shortest time

At Sinit in Bad Schwalbach, the AGV has helped to streamline processes in the areas of assembly and logistics in a very short space of time. This has increased productivity in a way that Sinit, an experienced and demanding company when it comes to automation, had hardly expected. With the fast and smooth introduction of the second AGV, EK Robotics has fulfilled all of Sinit's expectations for the project. "We were able to significantly increase our delivery performance and the AGV delivered the best results after just a short time. We are very satisfied!" says Thomas Wisser.

The high degree of automation, which has received a further boost with the systems from EK Robotics, is considered crucial in Sinit's industry in order to remain competitive. It is interesting to note that the external impact of the Vario Move transport vehicles is now also clearly noticeable, reveals Thomas Wisser: "In our day-to-day business, the transport robots are hardly noticeable, so much so that they have become an integral part of the company. However, as soon as new customers, service providers or employees enter our factory and we explain our processes and AGV technology to them, we realize once again what a milestone we have set together with EK Robotics. The wide eyes and the feedback we receive from our stakeholders are the greatest compliment."

This article appeared in issue 10/23