Valk Welding: Handling robots

A Revolutionary New Package for Aluminium Foil

Signode - The aluminium industry is about to see a transformation in the way aluminium foil is packaged thanks to the development of a unique new packaging process by Signode.

FOILRAP™ is a new robotic system for the transit packaging of aluminium foil coils via a ‘cocoon’ of stretchwrap film.

 

Signode has invested significantly in the development of this new innovation, which offers major benefits to foil producers compared with traditional methods of packaging. Having developed initial prototypes Signode has now finalised the process, introducing significant technological innovations. The result is a system that provides a much more secure method of packaging aluminium coils, thereby eliminating the possibility of contamination and the ingress of dirt during storage and transit. The FOILRAP™ storage process enables foil packaging to be carried out without operator intervention, helping to eliminate the potential for contamination of the product. In addition, not only is FOILRAP™ faster and lower in cost than traditional packaging methods, it also offers easier and cheaper recycling of a simple packaging material for foil producers and their customers. Patents worldwide have already been applied for both FOILRAP™ and the branded RAPFOIL™ film are registered trademarks.

 

Lower costs

With the FOILRAP™ process, aluminium coils are wound onto a mandrill in the conventional way and then transported to the packaging area. The mandrill is securely picked up by the material handling equipment and positioned ready for the wrapping process to begin. The robotic FOILRAP™ Machine determines the individual coil size to be wrapped prior to starting the cycle. RAPFOIL™ film is first gently secured to the belly of the coil by applying double sided tape automatically from an integral dispenser. The wrapping head then applies several film layers to the coil belly and over the edge, and then travels towards the coil ends, wrapping and sealing the ends up to the mandrill to eliminate the possibility of contamination. Once one end has been wrapped, the machine completes the opposite end, sealing the coil completely and protecting it from damage and dirt ingress. When the wrapping process is complete, the stretch film is cut and the film end secured automatically to the coil belly. The machine then retracts from the wrapped coil and is ready for the next cycle. The finished coil is then placed in a steel stillage, ready for warehouse storage or delivery to customer. The FOILRAP™ system offers significantly lower packaging costs than traditional methods with typical savings of around 70% on both labour and material costs. The entire packaging process is also faster and more efficient, helping to increase plant productivity.

 

The FOILRAP™ system also delivers major benefits in terms of recycling, as previous methods have required customers to return waste packing to the aluminium producer where it would have to be manually sorted into different materials types and then disposed of. By using a single material, FOILRAP™ ensures packaging waste is kept to the absolute minimum making recycling simpler, less time-consuming and at lower cost. The branded RAPFOIL™ film is very clean and easy to recycle as it can be easily removed from the coil and compressed into a bale. These bales can then be sold on to local recyclers by customers, which not only reduces disposal costs for producers but also provides a clean saleable polyethylene product for their customers. The sides empty stillages are then folded flat for the return journey and together with mandrills are simply retuned to the producer on the delivery vehicle, ensuring no extra delivery costs are incurred. An additional benefit is that the steel stillages have a much longer life than traditional wooden crates which are prone to damage and costly to replace.

 

Fast operation

The design of the FOILRAP™ system means that it can be installed in virtually any foil production operation. For example it can be mounted to a floor, wall or ceiling frame or even on a carriage, allowing operation in different locations. The FOILRAP™ robotic system can easily operate within a 180° position. Once the wrapping sequence of first coil is completed, the FOILRAP™ machine can rotate into a new position to start the wrapping cycle of a second coil thereby offering the potential for a continuous packaging process, which reduces costs still further. The system is faster than alternative methods, with the entire wrapping and packaging operation taking approximately up to 3.5 minutes depending on coil size. It is also very economical, as an average of 50 aluminium coils can be wrapped from each roll of RAPFOIL™. Because the coil ends are sealed by film the possibility of contamination by dust and dirt ingress is eliminated. The result is improved product presentation, a more secure method of packing high cost ultra thin foils and reduced possibility of damage during transit. The only operator intervention that may be required is during the film roll changeover. This process takes only a few minutes and the option of an automatic coil change facility is available if required. This minimal operator contact helps to reduce costs and further prevent the possibility of contamination. FOILRAP™ is suitable for coil dimensions from 600mm to 1200mm and lengths from 650mm to 2,000mm with other sizes available to special order. Signode has already established it’s innovative approach to the industry with the introduction of TENAX® high strength polyester strapping systems. This system has proved so successful, that the majority of aluminium ingots, billets and slabs are now secured using this method. With FOILRAP™ we are confident Signode has developed another ground breaking packaging system for the aluminium industry,” said Gerard Laks, General Manager of Signode Dinex at Signode System GmbH, Germany W. Europe and Global Aluminium Specialist.