Hanyang Packaging and Engineering Enhanced Productivity and Efficiency Through Delta Robot

Packaging Company Enhances Productivity

Challenge

  • Increased market demand called for a solution to decrease human error and increase overall productivity.

Solutions

Results

  • Increased productivity without additional hiring
  • Sales more than doubled from last year
  • Reduced operator workload
  • Return on investment improved

Standardized packaging with speed and efficiency by advanced motion solution

One of the most popular traditional snacks in Korea is made out of laver, or seaweed (in Korean, ‘kim’). Like cookies in western culture, Korean dried laver is well known for its good taste and diversity of flavor. With influence of the Korean Wave, including K-Pop, Korean food is becoming one of the hot trends among many Asian countries.

Hanyang Packaging and Engineering, Inc., one of the largest packaging companies in Korea, is a packaging automation company that designs, manufactures and installs automatic packaging machines such as three-side packaging machines and automatic feeders. The company has extensive experience in automatic packaging machines and front/back feeders.

In recent years, Hanyang have grown into a company that can provide a total solution for the F&B packaging industry in a simple packaging company with a lineup from the “Kim” supply conveyor to the automatic feed conveyor that supplies that container supply device, the cutting device and the packaging machine.

Seaweed is very thin material and can be cracked during the packaging process; therefore, the packaging is processed manually. As market demand and production increased, Hanyang packaging decided that implementing automated solutions by advanced machines was a viable alternative.

Challenge

Along with the increasing demand from the market, Hanyang was facing two major challenges. First is delivery delays due to human error. Inefficiency has increased due to human errors caused by manual handling of seaweed pavement, delayed delivery of goods due to inaccuracies and lack of flexibility.

Second, as market demand grew, there was a need to increase productivity and output. As the existing labor force made it difficult to meet the production needs, Hanyang wanted to implement an automated solution for itself.

The most widely sold from Hanyang Packaging and Engineering: A laver cutting machine that includes automatic feeding conveyor, cutting device and desiccant feeder.

Solution

To keep up with the increasing demand, Hanyang Packaging took an innovative approach to smart machine design. Unlike conventional equipment that includes a separate robotic control environment, Delta Robot by Rockwell’s Integrated Architecture relies on one control platform for the entire system — from robotics control to indexing and conveyance. Unlike traditional equipment that includes a spate robotic control environment, using only a single control platform enables improved connectivity both in terms of network and hardware.

Integrated Architecture is real-time control and information delivering smart manufacturing, machines and equipment. As part of the Integrated Architecture system, the CompactLogix 5370 L3 controllers use the same programming software, network protocol, and information capabilities as all Logix controllers, providing a common development environment for all control disciplines. The single control environment means the entire system can be managed from standardized controllers and one control touch screen. The function of kinematics within the controller added to the overall machine design simplicity and easier accessibility to maintain.

In addition to the CompactLogix controller, the Rockwell Automation system includes Allen-Bradley® Kinetix® 5500 servo drives and VP-Series™ servo motors. The servos control the Delta Robot as well as the indexing motion exactly.

“One Allen-Bradley® CompactLogix® 5370 controller provides all the processing power we need from beginning to end,” said Kee Hoon Kim, Solution Architect from Rockwell Automation. "By integrating robots and all servo drives into one controller, and Kinematics in Logix's standardized CIP Sync / motion platform, we can easily control advanced motion by maximizing user programmability."

The loader is monitored by using Allen-Bradley PanelView™ Plus 7, ideal for applications like monitoring, controlling and displaying information in dynamic ways where operators must quickly understand machine status and make better decisions.

Result

With this solution, Hanyang Packaging has improved productivity and efficiency and reduced costs with a single common control platform, common network and design environment.

Hanyang Packing introduced the Delta Robot with the Integrated Architecture from Rockwell Automation for the first time in the Kim packaging industry and now has the best reference and overwhelming market share in the field. We are providing total solution in one F&B packaging industry.

Success of this project has been a great help from references to successful examples from Rockwell Automation references. Customers have had a good understanding of the high-end Delta Robots that can only be realized by Rockwell Automation products and solutions through many references.

The success of this project can be seen from two perspectives. From the end-user perspective, the new equipment allowed hanyang to manage peak summer production in the summer without having to hire an additional 10-15 employees. In addition, from an OEM perspective, sales automation increased by more than twice as much as last year, and Investment payback Period also declined over the long term, resulting in a six-month ROI.

Allen-Bradley, ControlLogix, Kinetix, MP-Series, PanelView are trademarks of Rockwell Automation, Inc.

EtherNet/IP is a trademark of ODVA. Laver Cutting Machine trademarks of Hanyang Packaging, Inc.

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