PC-OCT22-PG12-13.1_Layout 1 05/10/2022 15:08 Page 12
HAZARDOUS AREAS & SAFETY
A complete one-stop solution from OMRON has ensured the safety upgrade of a folder-gluer machine at Smurfit Kappa Zedek
SAFETY UPGRADE ON FOLDER-GLUER MACHINE W
hen manufacturing companies need to automate and streamline their operations, it makes sense to partner with another company that can provide a wide range of products and services. However, it’s important that the chosen partner has all the resources, technical expertise, and experience to fulfil any needs. When Smurfit Kappa Zedek, a producer of corrugated packaging material and high-quality displays, needed to upgrade the safety aspects of one of its key machines, it found the perfect fit with OMRON Industrial Automation. Smurfit Kappa Zedek is part of the Smurfit Kappa group, a leader in paper-based packaging. The Smurfit Kappa Zedek’s manufacturing operations are based in Deventer, the Netherlands. The company specialises in the design and production of corrugated cardboard packaging and point- of-sale displays. The packaging can be printed in full colour using either offset or digital printing.
One of the key machines at Smurfit Kappa Zedek’s production facility folds and glues the corrugated cardboard packages. This machine is over 22 years old, so needed upgrading to comply with current safety standards. Huib van de Made, Manager of Safety and Quality at Smurfit Kappa Zedek, explained: “In line with our philosophy of continuous improvement, we wanted to ensure that we’re using the latest, state-of- the-art technology that can provide the
12 OCTOBER 2022 | PROCESS & CONTROL
highest levels of safety for our operators. At a seminar at Smurfit Kappa Benelux, OMRON spoke about functional safety. Their ideas exactly matched what we had in mind.” Following this, the company carried out a safety upgrade review of the folder-gluer machine. This was completed in conjunction with OMRON, who were invited to see how the machine could be modified and upgraded to meet the latest regulations. The different legal requirements, CE approval and the validation of the machine were key priorities for the company. Following the review, OMRON helped Smurfit Kappa Zedek to develop a completely new safety concept.
OMRON’s total safety services solution included machine risk assessment analyses and the design of the safety solution. The latter involved analysing the work of operators using
the machine and taking into account the maintenance plans, in order to maintain production efficiency throughout. OMRON also arranged for the remediation of the solution through the delivery and installation of all the required electrical and mechanical components. Finally, OMRON provided full validation of the installation and training, including all of the relevant technical documents and reports.
The key components of the new safety solution included the safety control solution; a trapped key system; the manual control, including position detection; and various safety items for the different production zones and the delivery belts (including emergency stop buttons and sensors).
While OMRON was the main contractor for all aspects of the project, the installation of the electrical elements of the safety solution was carried out by OMRON’s partner, MDE Automation. Smurfit Kappa Zedek’s Technical Services team undertook the mechanical part of the installation. The entire implementation was completed in four days, including the validation of the solution by OMRON on the final day.
Huib van der Made continued: “One of the main challenges involved ensuring that people would be able to do their jobs safely, effectively and quickly. This meant that our workforce needed to be open to new developments.” OMRON’s safety services ensure that maintenance and production are
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