Radar on robot wrappers

Robot wrappers have the edge over semi-automatic turntable wrappers on flexibility, but companies looking for speed might be want to consider other wrapping options, writes Lynda Searby

Robot wrappers have come a long way since the first one was invented by Robopac in Italy in 1982. The early mechanical machines have been succeeded by more sophisticated electronic systems, and self-propelled robot wrappers have firmly established themselves alongside other semi-automatic stretch

wrappers like turntable wrappers and rotary wrappers.Gordian Strapping, whose range takes in the Motion and

E-Motion robot wrappers, estimates that robot wrappers represent 18-20% of the market, with turntable wrappers accounting for 80%. The company says semi-automatic rotary arm wrappers tend to be less popular, accounting for 3-5% of the market.

It doesn’t seem likely that this dynamic will alter dramatically in the next few years, although there is evidence to suggest that robot wrappers will make some gains, potentially at the expense of other wrappers.

“I wouldn’t say that robots are growing dramatically in popularity. But there are more companies building them than there were 30 years ago. Sales are growing at the same rate as turntable wrappers,” observes Daren Spice, sales and marketing director at Gordian.

One of the newer entrants into this space is Southgate, which launched its robotic stretch wrapper offering, the RSW6, last March.

Since its introduction, the RSW6 has “provoked a lot of interest, with healthy conversion to orders”, reports Southgate.

Robots wrappers excelEven if there is still potential for growth in the market, robot wrappers will never be as common a sight on packaging lines as turntable wrappers, because they are not suited to every applica-tion. That said, they offer flexibility that is invaluable in certain applications.

As Martyn Sumner, load retention specialist at Kite Packaging, puts it: “Robot wrappers are in widespread use but they have unique features that make them the right solution in some circumstances but not in all.

“If you are looking for a mobile option they are great; if you have large or unusual shapes to wrap they are perfect; if you have unstable loads they are excellent. They can wrap any size pallet, and as pallets do not have to be placed on the turntable and then turned to fulfil the wrapping, this avoids stability and H&S issues.”

Southgate’s marketing manager Darren Smith agrees: “A robot

Kite Packaging: robot wrappers are now in widespread use

Kite: robots can work well as a mobile option

Pallet stretch wrapping Technology Focus

May 2019 Packaging News 37

wrapper isn’t limited to a maximum pallet width, length or weight – it could even wrap a shipping container. A robot wrapper can also be stowed away and moved to where the wrapping is required rather than occupying a fixed location,” he says.

Besides pointing out the speed (no need to wait for a forklift truck) and space (storage when not in use) advantages of a robot wrapper, Gordian’s Spice highlights rework as another application where robot wrappers prove their worth.

“If a big company uses a fully automated ring wrapper but needs to take QC samples or to rework pallets, once the stretch wrap has been opened, the pallet is too unstable to put back into the automated line so the robot comes into it’s own.”

Weighing up the costThese advantages do come at a slight premium; Gordian puts the average price of a turntable wrapper at £4-5,000, and that of a robot wrapper at £6-7,000.

These estimates tally with Southgate’s figures – Smith says robot wrappers cost about 20% more than a turntable wrapper with comparable features.

Kite’s Sumner agrees that robot wrappers are slightly higher priced than your average turntable, but points out that “the larger the turntable, the more you will pay”, and that the robot wrapper’s flexibility justifies its price tag.

“With a robot, you are paying for the benefits. Due to them being free-standing and able to wrap a pallet of any size, the robot offers more flexibility. Also, in circumstances where you may need to wrap pallets in a number of different locations, this would

RESPIREX BREATHES EASY AFTER ROBOT WRAPPER INVESTMENTAn investment in a Motion MPS robot wrapper from Gordian Strapping has increased wrapping efficiency and reduced film usage by 60% at Redhill-based protective clothing manufacturer Respirex.

Respirex specialises in the design and manufacture of high-performance chemical, particulate and respiratory protective clothing and specialist protective footwear, supplying customers around the world from its UK factory.

The Surrey-based company

was looking for a semi-automatic wrapping machine to improve efficiencies in its dispatch department. Space constraints meant that a traditional turntable wrapper was too big. A robot wrapper, which can be stored neatly away in a corner when not in use, was the ideal solution.

The Motion MPS is a self-propelled robot that can wrap pallets of any size, weight or shape. The machine uses power pre-stretch film, rather than hand pallet wrap, which

Respirex had been using previously. It stretches the film by up to 250%, laying it onto the pack with a measured resistance to ensure optimum pack presentation and load securement without damaging the packs. Stretching the film results in substantial cost savings and less packaging waste and because the film is being stretched, less reels of film need to be held in stock.

Before the robot wrapper was installed, Respirex was wrapping around 20 Euro

pallets a day by hand, some of them up to 1.98m tall. Automating the wrapping process means that the warehouse team can prepare the next pallet while one is being wrapped, thereby saving time.

Ayaz Asad Khan, warehouse logistics manager at Respirex says: “The robot wrapper has increased efficiency in our dispatch department and we’ve also seen around a 60% reduction in the amount of stretch film that we use.”

NEW TECHNOLOGY ROUND-UP: WRAPPING AND STRAPPING2019 sees the launch of two new strapping machines from Gordian. The SQ-800S is specifically designed to strap bundles of products like plastic pipe, aluminium extrusions, wooden dowels and metal rods. It features a miniaturised 23.5mm wide sealing head, enabling bundles as small as 40x30mm to be secured. The SQ-800SUS is a new machine for high moisture environments such as meat and poultry operations, or where stainless steel is specified for hygiene reasons, like pharmaceutical or clean room applications.

Kempner says its new APW-6040ST sleeve wrapper and tunnel combo packaging machine is the

most simple sleeve packaging solution on the market, designed to wrap collations of cans, jars, bottles and cartons, with or without supporting trays. Unlike conventional two roll sleeve sealers, the APW-

6040ST is a single roll sleeve wrapper, but is said to achieve the same result as a two roll machine. Other advantages, according to

Kempner, are that the system is inexpensive, does not require compressed air and is quick to changeover thanks to easy film loading.

Marpak Extrusions, a supplier of polythene packaging for the container glass and furniture industries, has introduced a new downgauged wrapping

film. The film is produced from Lumicene Supertough,

a bimodal metallocene-based resin whose molecular weight distribution allows

for production of thinner film without compromising on strength and rigidity.

Kite Packaging has added ‘low profile’ models to its Masterplat and Rotoplat ranges, giving customers the option of a stretch wrapper with a lower turntable height, so the ramp takes up less floor space. Ramp size is reduced to 325mm for space saving versus a standard machine, and, due to the reduction in turntable height from 77 to 30mm, there is a lower angle slope for more stability when loading pallets on the machine. A further benefit of this design, according to Kite, is that the machine can be

accesed from any side with either a pump truck, PPT or fork lift.

Southgate has added three new products to its

pallet wrapping and strapping portfolio: a robot wrapper, a cordless friction weld strapping tool and a bio-compostable stretch film. The Optimax RSW6 robotic stretch

wrapper is billed as offering fast,

consistent wrapping of loads that are too large for turntable or rotating arm wrappers; the main feature that distinguishes the new Optimax RXT range of cordless friction weld strapping tools from its

rivals is a rugged touchscreen that will survive tool drops and minor impacts; and the new compostable film is compatible with power pre-

stretch machines such as the RSW6 and Optimax PSW turntable wrappers.

Shrink wrapping solutions provider Yorkshire Packaging Systems has expanded its product range for 2019 to take in stretch wrapping machinery and a full complement of stretch wrap film to the UK market. For its fully automatic stretch wrappers, the kit

supplier has partnered with the Italian

manufacturer Tosa Group (Mimi), whilst

for its semi automatic range the

Yorkshire firm is working with UK-based Robopac.

Accoding to YPS, the equipment’s standout

features include intuitive touchscreen systems, water-proof wrapping cycles, film carriage safety stops and pallet height recognition sensors which reduce operator handling requirements and film waste.

Kite Rotoplat

Gordian SQ-800S

38 Packaging News May 2019

Technology Focus Pallet stretch wrapping www.packagingnews.co.ukpackagingnews.editorial@emap.com

result in a higher cost if you had to place a turntable in each location, whereas with a robot you can easily move it around. Using a robot also takes away the need for manually lifting pallets onto turntables,” says Sumner.

Consider the consBut robot wrappers aren’t the best choice for every application.

“If you require very high speed or have limited wrapping space, they may not be the perfect option,” says Kite’s Sumner, adding that robot wrappers won’t work on very lightweight pallet loads.

“The pallets need minimum weight because if they are too light, the guide wheel will not be able to sense the pallet.”

According to Southgate, speed is the main limiting factor for robot wrappers.

“A robot isn’t fast enough for high volume wrapping of conventional pallet load sizes or compatible with in-line wrapping, so it will never hold appeal for those sectors,” says Grantham.

Grantham points out that a turntable is faster than a robot and can be accessed from a wider angle of approach than a rotating arm wrapper, making it the best option for high volume, non-inline pallet wrapping. For in-line wrapping, Smith’s advice is that a rotating arm wrapper is better as the orientation of the pallet remains the same and it can be fed through the wrapper on a powered conveyor.

A step up from semi-automatic wrapping systems, automatic turntable wrappers and rotating arm wrappers present higher speed options. Then, for companies wanting a fully automated wrapper, integrated with their conveying systems, there are ring wrappers, which costs upwards of £65,000, according to Gordian’s estimates.

With a robot, you are paying for the benefitsMartyn SumnerKite Packaging

Kempner: sleeve wrapper

YPS

Marpak film extrusion