FEATURE CHEMICALS & PHARMACEUTICALS
KEY STEPS IN THE AUTOMATED HANDLING TRAYS DESIGN PROCESS
requirements? - The type of validation and transit testing (drop, vibrations and compression) / conditioning / sterilization / stacking weight / height that will need to be performed
Handling Trays
Marc van Keulen, lead designer, and Seán Egan, director of Global Marketing & VoC Development, Nelipak Healthcare Packaging
A
utomated handling trays play a critical part in the automation
process for internal and external transportation of critical components or devices where speed, efficiency and high tolerances are necessary. Choices at all stages of the automated handling tray design process can substantially impact outcomes and have the potential to build a competitive advantage. Since it is typical for more than one supplier of automated systems to be involved in decisions related to positioning and handling of components and trays, an expert healthcare packaging partner can act as an intermediary between all of the participating parties. Involving a packaging partner early in the project enables the best results to be realized for the user.
#1 VISUALIZE THE COMPLETE STORY The first step of the handling tray design process is to identify the intended functionality of the tray and determine specific logistics. Involving the packaging partner in this step can add maximum value by considering where, by whom and how the tray will be used to design the product for optimal manufacturability. This holistic view enables requirements, and even possible extra functionalities, to be established. At this stage of the design process, it is
28 SEPTEMBER 2020 | IRISH MANUFACTURING
critical to examine: - What the orientation of the part and the tray in the assembly line will be - Where, how and by whom will sterilization and assembly be performed to create the final product - The kind of protection that is needed for the products or for stacking purposes (dust protection, anti-static, stability, etc.) - If there are options for different type of trays or end-user packs - The dimensions of the pallet that will be used for transport to all parties involved - If transport will occur by air, sea or truck and what the dimensions of the transport container will be - Requirements for packing and storing conditions of loaded trays (moisture, air temperature, light, barrier bags/lidding, straps, etc.) - The inner and outer dimensions of the box - The allowed carrying weight of the box or stack of trays - If the tray size will fit on the existing automated line, conveyor or box, tub, crate - Will this be a cleanroom or non- cleanroom product? - The product lifecycle – will it be a single trip or reusable tray? If reusable, how many cycles and cleaning
#2 PERFORM CONCEPT SKETCHING Once there is a clear picture of logistical needs, concept sketching is recommended in order to verify the requirements and expectations of all parties involved. At this point in the process, create a clear “3-D” visualization of different potential variations – making sure all parties agree. Collectively planning around these factors can lead to quicker response times and a smoother process overall. When analyzing, volume studies may be performed to confirm the preferred orientation/stacking direction and quantities of components and determine allowed tolerances of tray and part positions, construction features, material options, features for ease of de- nesting and other important factors.
#3 CONSIDER ALL TRAY MOVEMENTS Whether manual or automated, all movements of the tray should be accounted for during every logistical step – including with stoppers, grippers, suction cups and/or conveyors. At this point, it is time to establish whether indentations will be necessary in the side wall for manual handling unloading the box. The handling speed of the individual trays and orientation on the conveyor should be decided, as well as quantities per tray, box, pallet or stack if required. The injection mold configuration could provide some idea for quantities or layout configurations that will result in complete packaging density. Another question to answer is How will the system detect the position of the tray (i.e. with light barrier, mechanical stoppers or cameras) must also be determined. By working collaboratively initially and
assessing crucial logistical elements during the design process, handling tray functionality can be optimized, and maximum value can be added during each phase. Down the line, CAD designs will then be used to finalize concepts and placement of functionality features before the prototyping stage.
Nelipak
www.nelipak.com / IRISHMANUFACTURING
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