cover story
retrofit custom conveyor system connects flow wrapper and case packer to keep the uk’s pets fed
When you need a bespoke conveyor system you might expect the costs to escalate. But this is not the case with Bosch Rexroth’s VarioFlow plus system that is configured with the user- friendly MTpro software tool; the same software also generates CAD files and bills of materials. A leading automation specialist in the UK recently benefited from this and the resultant high- quality plastic chain conveyor solution when it undertook a retrofit project at a pet food factory.
constraints were imposed due to the machine layout, factory layout and the need for a single- lane conveyor to feed four conveyors via a custom-designed pivot unit. a standard conveyor was out of the question and standard modules could not be combined to create the necessary conveyor system, so a degree of bespoke work was required. furthermore, the specification called for stainless steel to be used in the construction, the end user dictated which motors were to be used, and timescales were tight both for producing the system and then installing and commissioning it. the end customer had specified the varioflow
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plus plastic chain conveyor system from bosch rexroth, who were also responsible for the design and fabrication of the bespoke drop chutes and side guides. bosch rexroth also installed the motors and integral variable-speed drives so the system could be partially tested prior to delivery. the retrofit conveyor system links an existing
flow wrapper and case packer. it comprises a single-lane conveyor from the flow wrapper, a one-to-four pivot unit to divert the packets of product, and four conveyors feeding the case packer. all conveyors are 120 mm wide, fabricated from stainless steel, with friction tops applied to the standard modular plastic conveyor chain links to transport packets of pet food reliably at high speeds of 60 m/minute or more. in total there are 11 conveyors with an overall length of 14 m. to integrate the conveyors with the flow
wrapper, case packer and four-way pivot, bosch rexroth had to produce curved conveyors with special radii. furthermore, the conveyors needed to avoid support pillars, pass over other parts of the machine and under a mezzanine floor. a major benefit of the varioflow plus conveyor system is that projects are designed using bosch rexroth’s mtpro software. this is not a traditional cad package requiring a skilled
ne of the uk’s leading manufacturers of pet foods needed to replace a complex conveyor system on a packaging line.
operative; instead, it is more akin to a 3d configurator that non-experts can use to create sophisticated conveyor systems with ease. engineers from bosch rexroth and the automation specialist could therefore develop the conveyor design together, working remotely due to the coronavirus restrictions. moreover, when a design is finished, mtpro outputs cad files and bills of materials for sharing and using in downstream manufacturing processes. engineers at the automation company were already familiar with varioflow plus and mtpro having used them on previous projects, so the workflow was particularly smooth for the pet food packaging conveyor system. when the design was complete the conveyor
system comprised a number of standard parts – which bosch rexroth already had in stock in the uk – and various bespoke items that were manufactured in Germany and delivered to bosch rexroth’s cirencester factory. the entire system, including the pivot built by the automation engineers, was then assembled and tested to check the operation as far as possible. following sign-off, the system was delivered to site for final assembly and commissioning by the automation engineers. steven morris, the rexroth engineer
responsible for the project, comments: “we were delighted to hear that the varioflow plus was the end customer’s choice. they were impressed with the quality, reliability and low maintenance of another varioflow plus system they were already using, so specified it for this project. we are now
6 september 2021 | factory&handlinGsolutions
working on a further conveyor upgrade for the same end customer, also utilising varioflow plus. “the pet food packaging line upgrade genuinely felt like a team effort. weekly ‘virtual’ meetings made sure everything stayed on track and, with our customer’s engineers already being familiar with varioflow and mtpro, we were able to share concepts and progress the design extremely quickly.” a major advantage of rexroth’s varioflow
conveyor family, particularly for this project, is that the products are standard – which minimises project risk and ensures high reliability – yet special versions can be produced easily and cost- effectively. furthermore, systems can be configured from a combination of standard and bespoke elements using mtpro, which does not require specialist skills. cad files are then generated fully automatically, which saves time and cost, and eliminates any risk of errors being introduced. these benefits are equally applicable for retrofits and upgrades, such as this pet food packaging project, or for new-builds.
Bosch Rexroth
www.boschrexroth.co.uk
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