Keramik Makina Sanayi ve Ticaret A.Ş
Introduction
It is obvious that packaging in daily life has a significant effect on consumption habits.The rising trends in the packaging sector, such as diversity, visuality, reliability, etc., are beginning to find a place and demand in the industrial field. Especially on the packaging side of the sectors that produce in high capacities such as cement; robustness, good insulation and cost reduction headings are scrutinized Sönmez Cement, which follows the packaging innovations in the cement sector, has started its permanent partnership with Keramik, which has more than 30 years of packaging experience by adding the Palletless Stacking and Packaging Line in among the investment items.
We want to explain a palletless packaging line that manufactured to Keramik customer who started to operate in 2014 and its annual clinker capacity is 1.7 million tons and its annual cement capacity is 2 million tons.
The Role of Keramik
As Keramik company, we are active in all areas where palletizing and packaging are available.Our company specializes in sectors such as cement, construction chemicals, gypsum, lime and manufactures innovative and sustainable solutions in many parts of the world. Robotic palletizing, coventional mechanical palletizing, high level palletizing, stretchwrapping, strapping, shrinkhooding, stretchhooding, palletless stacking and packaging lines are included in our portfolio
In tihs customer; we commissioned a flexible modular solution palletless stacking and packaging line which can be managed the product variety and capacity and also be reduced the initial investment and operating costs.
Palletless Stacking and Packaging Line
We can produce 50 kg, 42,5 kg, 25 kg Kraft or PP bags upon request and the total capacity of the line is 2400 bags / h. It can be used 5 and 6 patterns. Bags coming from two different filling stations are transferred to the stacking-packaging area by line combining.
The mentioned line consists of high speed bag transfer (line combining) conveyors, weight cheking and reject system, high level palletizer (with pallet magazine), top film dispenser, I. Stretchood, stack turning unit, II. Stretchhood, sling bag loading solution as an intermediate station, stack lifting and open sling loading system
Line Combining Conveyors
The bags which come from two different filling stations are conveyed to the transfer point with high speed bag transfer conveyors. From there, the bags continue on a single line according to the course of traffic flow.
Weight Checking and Reject System
The weight of the bags are continuously checked. When an out of tolerance condition, the reject system separates the product from the line and integrates it into the system..
High Level Palletizer
Main equipment; gravity conveyor, bag flattener unit, bag rotating system, layer pusher unit and mechanical stacking group
Gravity conveyor; ensures feeding and speed continuity
Bag flattener unit; ensures a homogeneous dispersion of the product inside the bag Thus a more stable stack is obtained
Bag rotating system; according to pattern information; the bags are turned or allow to pass directly
Layer pusher unit; the pattern on the relevant layer is generated and transferred to the mechanical stacking group
Mechanical stacking group; the layers are stacked on top of each other by shutter and lifting system.
Pallet Magazine; at the modüler line; when the pallet magazine station is added, the stacks can be shipped with pallets.
Top Film Dispenser
It is used to lay a base protector on the stack before entering the Stretch Hood Machine.
I.Stretchhood Machine
The stack is covered to certain point. The rest of stack is hooded at the second stretchhood operation
Stack Turning Station
After first hooding, the stack is turned 180 degress and transferred II. stretchhood
II.Strecthhood Machine
The rest part of stack is covered at this station
Sling Bag Loading Solution
Before stack turning station, the operator covers the stack with sling bag inversely which come from directly I. Stretchhood without hooding operations. After turning phase the top of sling bag is tied
Stack Lifting and Open Sling Loading System
Open sling is layed on platform by operator after lifting system picks up the stack and places on platform. Operators tie the slings and attach at lifttruck’s forks
Conclusion
Having its own port makes it possible to export to many different continents and countries quite easily. At this point, with the new line established by Keramik, the company focuses on export, while reducing packaging and logistics costs at long distances in other respects maximizes the quality.
Thanks to this line, our customer can produce both packing with pallet, palletless, sling bag, open sling and stretch hood packaging types on the same line.