Optimize production capacity in confined spaces with an intelligent, modular conveyor system. This solution enhances accessibility, safety, and vertical material flow for Consumer Packaged Goods (CPG) lines. It addresses complex integration challenges, ensuring continuous operation and strategic supply chain diversification for improved efficiency.
In the fast-paced world of Consumer Packaged Goods, every second and every square meter counts. Modernizing packaging lines, especially within existing, multi-level, and spatially constrained production facilities, presents several core challenges for material handling. A primary concern is maximum accessibility, requiring clear and safe "walk-throughs" for operators to access all machines, which is essential for smooth operations, quick maintenance, and employee safety. Another challenge is space-saving vertical transport: products ranging from individual wrapped items (like soap bars) to full cartons need to be moved across multiple levels without blocking valuable floor space, a conflict often posed by conventional solutions. Furthermore, maintaining continuous production during facility upgrades is crucial, demanding solutions that allow for flexible, phased integration into ongoing operations without extended downtime.
An intelligent and modular conveyor concept addresses these complex requirements by combining various conveyor technologies, perfectly tailored to specific product types and spatial constraints, to create a seamless, robust, and highly efficient material flow solution.
Technical Solution
For the space-critical vertical transport of individual soap bars, an extremely compact and clever solution was implemented: 18 Bosch Rexroth Alpine Conveyors (9 for elevation, 9 for decline) handled the task. Their design makes it possible to cover significant height differences within a minimal footprint, thereby freeing up valuable floor space for walkways.
For transporting the larger cartons, proven technology was utilized: 6 Bosch Rexroth Spiral Conveyors (3 for elevation, 3 for decline) ensured the stable and reliable vertical transport of the secondary packaging.
The horizontal sections connecting the various process steps were realized with a flexible system:
120 meters of the VFplus chain conveyor system
75 meters of a modular belt conveyor
This combination not only enabled precise integration into the existing infrastructure but also created a seamless, robust, and highly efficient material flow solution — including the complete control technology, installation, and commissioning by our team of experts.
Key Features & Benefits
Optimized Plant Accessibility & Enhanced Safety: The walkways created by the targeted use of Alpine conveyors guarantee the customer free and safe access to all equipment. This improves daily operational efficiency and significantly increases workplace safety.
Maximum Flexibility: The combination of different Rexroth conveyor systems provides a technically elegant solution, adapted to each product, for the reliable transport of primary and secondary packaging within a single, harmonized system.
Strategic Independence: As a new strategic partner, we helped the customer mitigate risks by implementing a two-supplier strategy, giving them greater flexibility and security in their procurement.
Economic Viability and Partnership: By leveraging local engineering and manufacturing capabilities, we were able to offer a competitive and economical overall solution that provides lasting strength to the customer.
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.