Conveyor technology & components
Ryll: From the individual pack to the mixed display
Picking chocolate bars in Solo KLTs to create mixed trays in ready-to-sell displays presented Ritter Sport with a challenge: it was necessary to combine the great flexibility of people with the efficiency of machines. Transportanlagen Ryll rose to this challenge.
The requirement: to design an optimum packaging and logistics line for chocolate bars that combines the highest possible availability and output with maximum flexibility. The space available (the line measures 50 × 20 meters) and, of course, the budget are further cornerstones of the line concept. Packaging for confectionery in particular is subject to seasonal fluctuations, which manifest themselves in different packaging designs and additional differentiated marketing strategies on the part of manufacturers. In concrete terms, this means that the chocolate bars are produced in different flavors depending on the season. These, in turn, are presented in different ratios in the displays.
In concrete terms, this means that the produced bars have to be transported automatically and just in time in their single-variety trays to the individual stations on roller conveyors. There, the bars for the supermarket displays are re-sorted into mixed variety trays by employees. The individual stacking trays are then automatically stacked into the quarter-pallet displays or onto the base box. At the same time, the displays (the individual cheeks and the top sign) are folded by machine, in some cases without tools, and transported to the delivery stations.
In contrast to the current trend in the industry to automate everything, a transport system that integrates personnel was explicitly planned. Manual processes can be adapted more flexibly to changes in the packaging. The short stages and the short shelf life of packaging concepts mean that this mixture of personnel and automation is more cost-effective in the long term. However, this also means that further requirements are placed on the transport system.
Transport systems Ryll designed ergonomically designed packing stations for this part of the system. According to Ritter, the system is a great success, as the output per shift has been significantly increased and costs have also been reduced thanks to lower staffing levels.
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