Automated Logistics for Hygiene Pack Packaging delivers high-speed, multi-format transfer for delicate, bagged consumer hygiene packs within confined, brownfield packaging areas. It ensures gentle handling, precise accumulation, and quick format changes for a wide range of soft packs, optimizing throughput to downstream equipment.
The core challenge involves automating the handling and conveying of consumer hygiene packs in plastic bags (primary packaging) from the forming section to downstream equipment. These products are typically soft, very light to light (less than 1 kg), and highly pressure-sensitive, requiring exceptionally gentle handling to prevent deformation or damage. Furthermore, these applications often require managing a wide array of package sizes, with up to 14 different formats varying significantly in dimensions.
Integration of such systems commonly takes place in brownfield environments within existing packaging areas. These settings are characterized by confined spaces and tight routing demands to downstream equipment, such as wrappers and case packer infeeds. Environmental conditions are typically standard industrial, dry, and room temperature, without specific wash-down requirements. Key process parameters include high-speed 2-to-1 merging, stable accumulation, and precise metering at high throughputs, often exceeding 100 packs per minute. The system must also support quick and repeatable changeovers for all formats using easily adjustable guides.
Technical Solution
To meet these demanding specifications, the technical solution leverages Bosch Rexroth's VarioFlow plus conveyor system integrated with advanced automation components.
Conveyor platform: VarioFlow plus chain conveyors configured as a compact main line with accumulation zones and a servo‑coordinated 2‑to‑1 merge.
Format agility: Tool‑less adjustable lateral guides across all sections to cover 14 bag formats; single‑touch conveyor concept to minimize handling points.
Automation: ctrlX CORE PLC with integrated HMI; frequency inverters and servo drives manage section speeds, merge timing, and accumulation pressure.
System integration: Interfaces to downstream equipment for handshaking and speed following; commissioning optimized for gentle acceleration profiles to protect soft packs.
Key Features & Benefits
Gentle Product Handling: Controlled pressures and smooth profiles protect product quality and reduce rework.
High-Speed Merging: Stable and synchronized 2-to-1 merging sustains target output (>100 packs/min) and reduces micro-stops.
Rapid, Repeatable Changeovers: Tool-less adjustable guides across all sections enable fast format changes for 14 SKUs, improving OEE.
Footprint-Efficient Brownfield Integration: Compact routing fits seamlessly into existing, confined packaging areas without major civil modifications.
Standardizable Architecture: The VarioFlow plus and ctrlX-based controls provide a reusable package for future lines, lowering total cost of ownership (TCO).
Build your Application with Bosch Rexroth Products
The solution shown here is based on a system that integrates various Bosch Rexroth components, including conveyor technologies, automation platform, and structural elements. Please note that you can also purchase these components individually from us to build your specific application. The links to the respective product pages are listed here.
Bosch Rexroth VarioFlow Belt Systems: Enable smooth and reliable transport of workpiece carriers up to 20 kg.
The Bosch Rexroth Aluminum Profiles and EcoSafe Protective Fence Components: Are flexible and ensure compliance and safety.
The ctrlX AUTOMATION Platform from Bosch Rexroth: Manages all processes and tasks and is a flexible gateway to other systems.