With the request for a flexible and efficient system for packaging palletized bagged goods from the chemical manufacturer from Emmerich am Rhein, a convincing overall solution was developed that went far beyond the originally planned scope. "The previous KLK packaging system was over 40 years old and also from the manufacturer MSK. The list of requirements for a new packaging solution included the maximum throughput of the system, a stable pallet pattern and packing patterns. We also opted for a hood stretcher," explains Jörg Bujar, Product Finishing & Logistics Team Lead and Dangerous Goods Officer at KLK Emmerich.

"The palletizing robot should be able to insert a cardboard layer between the wooden pallets and the bags, which avoids bag defects. Furthermore, each pack is inspected for foreign objects using a metal scan. Together, we configured the entire system in such a way that customer complaints are avoided and the system can follow KLK Emmerich GmbH's future path into the food-feed pharmaceutical sector."

It turned out that the system manufacturer MSK was able to supply all the necessary modernization and automation requirements with connection to the existing bag filling line from a single source. A tailor-made concept for the KLK plant in Emmerich with a bag conveyor including scales, labeler and metal detector as well as a modern palletizing cell with flexible and multifunctional robot technology, a sustainable packaging system for securing the pallet loads with a stretch hood and an automatic pallet conveyor to the warehouse now ensures a completely automated, efficient final packaging concept.

In particular, the overall MSK Emsy control concept ensures smooth communication between all areas of the system and a material flow without interface problems. "The new system is not just a replacement investment. We will use the entire system to supply our customers with even higher quality and take future steps with higher quality requirements," explains Jörg Bujar.

Multifunctional robot cell

The MSK palletizing cell installed in Emmerich is a multi-talent that performs many tasks simultaneously in a very small space. The bag palletizer picks up the 25-kilogram bags fed on an MSK bag conveyor gently and safely and stacks them flexibly on carrier pallets according to the desired packing pattern. Empty pallets are automatically loaded via a statio

empty pallet magazine. The robot also performs tasks such as placing bottom layers from a tray magazine and ejecting products if defects are detected as part of the quality check. The control system receives the information for this by networking via the MSK Emsy software, which also includes the integration of scales, labelers and metal detectors to check each individual bag.

Compared to the previously installed layer palletizer, the new robot palletizing solution proves to be significantly more flexible, space-saving and precise in layer formation. It is also particularly low-wear and therefore less susceptible to servicing and maintenance. Spare parts are available for a long time due to production in MSK's own factory. By integrating the palletizing cell into the overall system, KLK benefits from a homogeneous documentation, software and spare parts structure, including service for the entire system, without any possible reservations by third-party companies. "The high availability of the system, good service and maintenance experience and the price-performance ratio convinced us to purchase an MSK system," reports Jörg Bujar.