Modelling, Simulation and Optimization of a Packaging and Palletizing System

Modelling, Simulation and Optimization of a Packaging and Palletizing

System

POPA Cicerone Laurentiu1,a, COTET Costel Emil1,b*, GAVRILA Stefan1,c

and IONITA Valentin1,d

1University Politehnica of Bucharest, Machines and Manufacturing Systems Department,

No.313, Spl. Independentei, sector 6, Bucharest, Romania

alaur.popa79@gmail.com, bcostelemilcotet@gmail.com, cgavrila.p.stefan@gmail.com,

dvalentin_gogu@yahoo.com

Keywords: packaging, palletizing, wrapping, storage, pallets, modelling, simulation, optimization.

Abstract. This paper presents a material flow management case study based on our research in

modelling, simulation and optimization for a packaging and palletizing system. The studied system

allows packaging, palletizing, wrapping and storage of several types of products within a food

company. For each type of product to be packaged and stored a material flow system simulation is

necessary in order to identify and eliminate the bottlenecks and to obtain an optimized system in

terms of productivity. Because the optimization algorithm is the same for different kind of products

we will illustrate our research using a single type of product. We will focus the case study on

packaging coffee bags in boxes. The boxes are positioned on pallets in order to create a stack that

will be wrapped for storage. We used FlexSim 7 simulation software for modelling, simulation and

optimization of the packaging and palletizing system.

Introduction

In the current economic context, companies from the food industry need to diversify their

product range and need to constantly improve their product portfolio in order to compete

successfully on the market and to achieve sales growth. Thus, the implementation of a system that

allows final products packaging, palletizing, wrapping and storage is a mandatory requirement for

any food company that processes different types of products. The paper objective is to illustrate how

making a simulation-based diagnosis of a packaging and palletizing system is necessary in order to

determine the optimal operating parameters and to avoid a loss of productivity if the product to be

processed is changed [1]. The packaging and palletizing system has the flowing structure (see Fig.

1):

• a packaging work point (Wp1);

• a wrapping work point (Wp2);

• 5 conveyors (C1, C2, C3, C4, C5);

• 2 robots (R1, R2);

• a forklift;

• a central storage system (Rack);

• 4 local storage systems (B1, B2, B3, B4);

• human resources.

For packaging and storage of different types of products sold by a company from the food

industry, some components of the system require changes of parameters settings for each new

processed product. To diagnose those changes we use a virtual prototype of the system. In our case

study these changes occur mainly at the packaging work point, at the wrapping work point, at the

conveyors and at the robots. To obtain better results, a quick modification of the settings for each

type of product should be made and a system simulation should be performed in which the

Applied Mechanics and Materials Submitted: 2014-08-04

ISSN: 1662-7482, Vol. 760, pp 205-211 Revised: 2014-10-08

doi:10.4028/www.scientific.net/AMM.760.205 Accepted: 2014-10-09

© 2015 Trans Tech Publications, Switzerland Online: 2015-05-18

All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of Trans

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structural elements (work points, transport-transfer systems, buffers) should be parameterized

according to the requirements of each product type.

Fig.1 The system architecture modeled in FlexSim 7

Thus, when the product type is changed, one can make the necessary adjustments quickly in the

system to obtain an optimal system operation.

The main system components

KUKA KR 180 PA palletizing robot (R1 si R2) has four rotation axis numerically controlled.

Technical data: repeatability: ± 0.35 mm; payload: 180 kg; supplementary load on arm: 50 kg;

supplementary load on rotating column: 250 kg; weight: 1240 kg; max. reach: 3040 mm; work

envelope volume: 72.7 mm3

The pallet wrapping machine FP480

The pallet wrapping machine FP480 can be used in the food industry, it has the film cutting and

pasting function at the end of the work cycle and it can apply the film automatically at the beginning

of the work cycle resulting a fully automatic wrapping cycle.

The pallet wrapping machine FP480 can be integrated with the following equipment: palletizing

robots, pallet labelling