Automated Production Line Stages and Processes

Mixing Station

Mixing Station

The mixing stage is the only stage that is not connected to the production line sequence and does not has any modern control technologies. This means that the stage is a standalone system that relies on simple actuation technology to perform the necessary process.

Filling station

The filling machine is an advanced, fully automated filling machine that integrates the supervisory level of automation systems with a programmable system that could be modified to suit a predefined range of production requirements. The machine is considered the main asset in the production besides being the most complicated one.

First Boxing and packaging stage of initially filled products The unit's task is to perform multiple operations. Firstly, is to extract a single box from a connected pallet of flat boxes using a series of linear and rotational pneumatic actuators connected to pneumatic suction cups. Secondly, the machine folds the extracted boxes to the required shape and present them to receive the oncoming prefilled bags from the filling station. Similarly, the operation is performed using a series of linear and rotational pneumatic actuators designed in specific alignment to execute the process efficiently. The last stage of the process is the closure and taping of the filled boxes. The process takes place using the same technology as the previously mentioned stages to operate and delivers the final sealed box to the following stage.

Second Boxing Stage

Following the production process, boxes that contain two single boxes have to be shaped and filled with the required boxes, then folded and taped, similarly to the tasks from stage 2. However, for such operation, individual stations of boxing, packing, folding and taping were used to perform such operations, rather than the use of the single station as at stage 2. The 2nd boxing stage handles the task of the extraction of individual boxes from a pallet of flat boxes then fold them to the required shape. The station work is done at this stage, and the created boxed passed to the following stage of packing the initially created boxes. The system is fully automated with a supervisory system in place that provides an insight into the number of the executed production cycles and the choice between a predefined set of parameters for the used boxes.

Packaging of Stage three Boxes into a Larger Box

The packaging station receives two different items, the single produced boxes from stage 2, and the folded empty boxes from stage 3. The station uses a pick and place mechanism to perform the task of picking up stage 2 boxes and then place them accurately in pairs inside the box from stage 3. The station uses a series of electrical and pneumatic actuators alongside a high number of sensory devices to perform the required tasks. The electrical servo motor actuators handle the vertical and horizontal positions of the connecting arm that is responsible for the pick and place processes. The system, as the previous systems had, includes a supervisory system that presents several predefined varieties of boxes sizes that could be used in operation. The finished boxes get delivered to the connected conveyor belt to deliver to the following stage.

Folding and Taping of Stage five Boxes

Takes the responsibility of folding and taping the received boxes from stage five, similarly to stage 2 and deliver the final product to the last stage of the process. Likewise, using a series of pneumatic actuators and a number of sensory devices, the machine can execute the application fully automatically. The system integrates an HMI screen to monitor and control the application.

Palatizing of Final Products

Using a more substantial pick and place machine, the palatizing stage performs the task of picking the final delivered product and place them in a setup of thirty-six boxes pallets. The system uses a series of electrical actuators to handle the positioning of the pick and place arm, beside pneumatic actuators that mainly handles the suction cups responsible for holding the boxes during the pick and place processes. The system integrates an HMI screen the provides insight about the status of a limited number of sensors besides providing a set of a predefined set of choices of different setups for the required Pallets.