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uni UPDATE Internal newsletter for Ammeraal Beltech modular sales organisation

December 2009

With the Roller Coaster, Hollywood Rocket, Directly to Santa in No Time.. Product of The Month: uni QNB uni QNB Plastic Modular Belts and The Corrugated Industry Recertification of Our Quality Management System 2009 in a Modular Perspective Modular Know-how Seminar on Infonet The Marketing Support Team in Ammeraal Beltech Modular Send you Christmas greetings

With the Roller Coaster, Hollywood Rocket, Directly to Santa in No Time..The gremlins teased us In the last edition of uni UPDATE, an unfortunate error appeared in the article about the roller coaster, Hollywood Rocket universal projects. The article mentioned that the roller coaster runs with a speed of 118 km/hour this is rather extreme, unless the roller coaster changes name to Rocket Express to Santa. The correct speed is 0.33 m/sec. We apologize for the incorrect information. Karin Lund

See Christmas Greeting 2009 from modular marketing page 11. True to tradition, this December edition of uni UPDATE contains some Christmas fun. We can reveal that this year some very special crawling pixies will be presented.We have received this very nice Christmas Greeting from Italy.

Ammeraal Beltech Modular A/S

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uni UPDATE Internal newsletter

December 2009

Story of the month/Product of the month

Product of The Month: uni QNB uni QNB Plastic Modular Belts and The Corrugated Industryuni-chains QNB plastic modular belts are now accepted as the new material handling standard in modern corrugated production plants. They are found on most new installations and are also being retrofitted into older production lines. The total installed volume of uni QNB plastic modular belts continues to grow each year as plant operators learn the advantages and understand they represent totally reliable solutions. Each year, many new plants fully equipped with thousands of square meters of uni modular plastic belts are built and hundreds of conveyors with uni QNB belts are now installed across the global corrugated industry. In addition the future still remains bright. In order to survive under current market conditions, corrugated plants must be lean and highly efficient, proven savings made by installing the automatic conveyor systems result in further investments still being made.

The beginning was very different. Traditional conveyor systems in corrugated plants used roller tracks, belt over roller and roller slat chain conveyor combinations. These all exhibited problems such as stack creep, resulting in an elephants foot stack profile, stack instability, snagging and toppling of stacks. On these traditional handling systems lower layers in stacks frequently have had to be written off because of contact pressure points marking sheets. Also dirt and surface oxides from rollers marked bottom sheets. Although the advantages of the plastic modular belts in the corrugated industry are now obvious, it took time to build confidence within the industry. Early progress in this industry was slow. Roller conveyors were very low priced and the first modular conveyors were expensive to build. Step by step the conveyor OEMS reduced the cost of construction and the installed base started to grow. Reliability is critical within corrugated production plants and from the beginning uni QNB proved to be very reliable, but this was achieved only after extensive co-operation and development carried out with our key OEM customers. Others have tried and failed, indicating the importance of attention needed to even the smallest details. News of the modular belt technology has now spread around the corrugated industry. When proposals are submitted for new installations the incorporation of plastic modular belts has now become the accepted standard solution.

Improve corrugated plant production flow and efficiency using unichains QNB plastic modular belts.Production of corrugated board is a high volume but very competitive manufacturing industry. An industry where only the very fittest can survive. uni QNB belt has become the belt of choice for automation of these corrugated plants.

Ammeraal Beltech Modular A/S

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uni UPDATE Internal newsletter

December 2009

Modern high performance corrugators produce massive volumes of product - a 3m wide corrugator running at 400m/min outputs 1200 square meters of board per minute. Without an intelligent automated materials handling system, it is almost impossible to remove and control flows of this tremendous product volume and at the same time coordinate downstream production activities. Traditional product removal methods via forklift trucks are no longer the economic option for these modern plants. Investment in an integrated intelligent handling system incorporating plastic modular belts has become the new standard for the corrugated industry.

Downstream from the corrugator, converting machines need constant feeding with an uninterrupted flow of board to ensure they operate at maximum efficiency. With several different converting machines operating, demand on the materials handling system quickly becomes complex and any delay in material supply results in loss of output capacity. The performance of the materials handling system thus determines the overall success of the production plant. Successful corrugated plant operation is all about FLOW not handling and storage. Flow between corrugator and downstream equipment is balanced using a work in progress storage area. The work in progress storage system is based around a series of parallel modular belt bi-directional conveyors fed by a transfer car. Stacks of products are automatically moved in and out of the store area as required by down stream processes. The modern corrugated plant is highly efficient and complex to control. Therefore fully automatic handling of products is a key to plant profitability. Good use of automatic conveyor handling systems combined with intelligent control software will maximise the production capacity of a plant by ensuring work flow, efficiency and greatly influence profitability.

Ammeraal Beltech Modular A/S

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uni UPDATE Internal newsletter

December 2009

uni QNB modular belt. A few examples of corrugated plant applications:CORRUGATOR TAKE AWAY CONVEYORS Output from the corrugator must be continually cleared. A series of conveyors are used to clear products away from the corrugator down stackers. uni QNB belts form a clean hygienic modern production environment. The plastic belt surface fully supports corrugated products being conveyed and ensures safe mark free handling. This full clean modular belt surface is especially an advantage when handling stacks of boards with sensitive liners, micro flutes, lightweight board and products intended for later direct food contact applications. Safety of plant personnel is critical to maintain at all times. Within a complex plant layout several points will exist where it is necessary for personnel to cross the conveyor system. Modular belt equipped conveyors with their flat surface offer major improvements compared to roller conveyors; you can walk on the modular belts. Personnel often cross conveyors in the stacker take away area, thus a much safer and cleaner working environment is obtained. To increase safety, uni-chains offer the option of uni QNB belt with special nonslip surface for use in pedestrian crossing areas. In addition yellow strips or yellow edge links can be incorporated into the belts to increase visual awareness of a moving conveyor surface. For higher output, plant transfer cars with multiple belts are provided to increase capacity to move the high volumes of product. Stacks of corrugated board are assembled on the down-stacker take away conveyors ready for collection by transfer cars which automatically take the stack to its next production process step or move the stack into the work storage area.

CROSS PUSHING Cross pushing is used to double sideways stack patterns. Two stacks are then loaded onto a transfer car simultaneously which results in faster car loading and response times. This arrangement is an advantage where long transfer car travel distance exists and improves system response times.

Ammeraal Beltech Modular A/S

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uni UPDATE Internal newsletter

December 2009

TRANSFER CARS Transfer cars automatically move stacks sideways across the conveyor system. The modular belts are bi-directional allowing loading and unloading from either side. Cars can achieve transit speeds of up-to around 3 meters per second thus quickly can reach the far locations and return in time to receive the next load of stacks.

Below: Note the high stack quality (straightness of stack) maintained after transfer from car onto storage conveyors

WORK STORE AREA

Ideally product will move immediately and directly from step to step through the converting process but in practice this flow is not always balanced, hence the need for work in progress storage. The work in progress area must be carefully managed and optimised to ensure overall operational efficiency. Excessive storage capacity and its misuse can lead to inefficient plant operation. Double height systems have been developed for plants requiring large storage capacity with limited ground floor space. Transfer cars incorporate conveyors mounted on lift tables to service both store levels. All store conveyors are bi-directional to allow loading and unloading from same end by a transfer car. Work storage conveyors in some plant layouts are arranged to allow transfer cars to access both ends, this

Ammeraal Beltech Modular A/S

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uni UPDATE Internal newsletter

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