Non-wovens, tapes and film rolls are indispensable in the medical, hygiene and industrial sectors. They can only fulfil their purpose if they are precisely wound onto rolls, securely packaged and processed. This is precisely where bottlenecks frequently arise in practice: large roll diameters, weights of up to 1,300 kg, sensitive surfaces and high cycle rates are met with increasing demands on quality, hygiene and process reliability.
Two projects, one solution
Two independently implemented automation projects from the chemical industry demonstrate how KOCH Robotersysteme masters these challenges. Despite a high degree of product variation, the systems automate the entire roll handling process – from unloading to load securing. The result is stable, reproducible24/7 processes and a significant reduction in manual intervention.
Engineering as the foundation for stable processes
The foundation is laid by KOCH’s comprehensive engineering services. These include detailed analyses, application-specific development work, as well as 3D simulations and VR walkthroughs that assess the system concept for efficiency and feasibility. Mechanics, robotics and software are precisely tailored to the product, weight, layout and cycle rate. This results in a clearly structured, end-to-end process in which each step logically builds on the previous one.
End-to-end process from roll unloading to palletising
During plant operation, an unloading robot fitted with a specially developed KOCH gripper handles each roll safely and gently. This is followed by labelling, including automatic barcode verification to ensure traceability. The packaging adapts flexibly to order specifications – wound axially or radially and, if required, supplemented with end caps, discs or cut protection.
Palletising is robot-assisted and highly precise. It makes no difference whether there is one roll per layer, several rolls side by side or in bundles, in single or multiple layers: the heavy rolls are positioned with layer-specific accuracy and stacked in a reproducible manner, with outputs of up to 120 rolls per hour.
Data that manages processes
Each roll is accompanied by a digital data record that is tracked throughout the entire production process. This data determines the type of packaging and the palletising pattern, enables the early detection of errors, and allows multiple orders to be processed in parallel or pallets to be temporarily stored if priorities change at short notice.
Modular automation with strategic added value
Both companies opted for KOCH Robot Systems partly because of the modular Big FIVE structure. Five flexibly combinable functional modules for roll unloading, packaging, palletising, markeing and labelling and load securing, combined with appropriate data logistics, enable tailor-made, scalable solutions. This makes automation a strategic tool that supports efficiency, quality and employees in equal measure, and ensures companies are sustainably fit for the future.
More information at: koch-roboter.de/kochbigfive/
