High productivity in packing boxes of all types and significantly improved ergonomics for staff: With an ERGOSA Universal Packer from Canadian manufacturer IMPACK, HEYNEN GmbH & Co. Kartonagenfabrik KG, based in Kleve, Germany, is taking full advantage of the possibilities of innovative technology at the exit end of its latest folder-gluer.

“We have to be flexible, while maintaining both productivity and efficiency. At the same time, we are using new technologies to continuously improve ergonomic conditions at our work stations. And we make our investment decisions in line with these objectives, keeping a close eye on the facts and figures,” says General Manager Joachim Gimpel-Henning, describing a cornerstone of his company’s philosophy. Compared to big competitors active across Europe and around the world, he says, the traditional packaging manufacturer is just a minor player. “But for that reason, we are much more flexible. We respond quickly to our customers’ requests and requirements, which in addition to high product quality and reliability is the main reason our company continues to grow with both existing and new customers.”

Pet food, pizza, flowers, spare parts, cleaning agents, shoes, seasonal articles like Christmas calendars and innumerable other products: HEYNEN’s customers order more or less all the folding carton styles. The company therefore must have the corresponding flexibility, and that includes its packing process. “For our newest folder-gluer, we were looking for a universal packing system that enables us to exhaust the high productivity and flexibility of the folder-gluer,” says print shop and glue line manager Karl-Heinz Souvignier, looking back to fall 2017. The company decided to equip the folder-gluer with an ERGOSA Universal Packer from Canadian manufacturer IMPACK, so as to avoid letting the packing process become a bottleneck in production. The modularly designed and extensively configurable IMPACK machine offers the flexibility of a semi-automatic packer, but comes close to the productivity of a fully automatic one. The latter was not an option for HEYNEN because of the wide range of different box types it produces. Short setup and changeover times were another requirement, since HEYNEN has to change over to a different product comparatively frequently.

Packing without the physical strain
The company also wanted above all to relieve its packing staff and take steps to safeguard their health. “The faster we run the folder-gluer, the more weight there is to be moved at the end of the line,” explains Gimpel-Henning. HEYNEN mainly processes solid board, which means a good 400 kg of folding boxboard per palette. With ten palettes per shift, that adds up to over four tonnes.

The IMPACK system at HEYNEN consists of an IN2B box turner for turning all box types to the right or left, a main conveyor with case ejector, a PERPACK pusher module and a case closer. Employees place previously erected cases in the PERPACK, which holds the flaps firmly, keeping them out of the way while the case is being filled. Next they separate a row of boxes – exactly as many as fit inside a case – from the shingle as it travels slowly into the machine, pull the row with both hands in between the pusher and case in front of the PERPACK and finally push the row into the open case. This last step is completed all in one go using the pusher – and without any significant physical effort. Once the boxes are in the case, the PERPACK’s conveyor module immediately tilts from a vertical to a horizontal position to clear the way for the filled case to advance to the closing unit.

The entire process takes just a few moments and appears to be very simple. No signs of rushing. Employees don’t need to lift or turn the boxes to place them in the cases. “We’ve reduced stress and physical strain to a minimum for our packing staff, but still achieved a higher throughput,” says Gimpel-Henning. It may be coincidence, but absenteeism due to illness has dropped significantly at HEYNEN since the ERGOSA was installed.

What’s more, system setup is very simple, and can be flexibly adapted. If a job changeover occurs, but the box type stays the same, only the format of the boxes and cases usually needs to be re-set at the ERGOSA. If a straight-line box is followed, for example, by a crash-lock bottom box, staff usually also have to adjust the settings on the IN2B box turner. “Setting up the ERGOSA takes anywhere from five to 20 minutes maximum,” reports Souvignier.

To ensure the highest level of efficiency in box gluing, HEYNEN has standardized the process. An illustrated logbook shows how to set up the folder-gluers and the ERGOSA for different jobs. For example, it has instructions on how specific box styles have to be turned by the IN2B for optimum packing in the cases. With its flexibility, the IN2B supports a number of options, but in practice, only one usually proves to be ideal, and it is specified in the logbook.

HEYNEN achieved its objective of exploiting the folder-gluer’s high productivity without additionally burdening packing staff. “When processing straight-line boxes, for instance, we can now run the folder-gluer up to 40% faster since we installed the ERGOSA,” says Souvignier. “Machine speeds are significantly higher today, especially for critical box styles.” The machine was installed in early 2018. HEYNEN was able to launch production using the new system almost immediately, with the support of an instructor from IMPACK, who spent about a week demonstrating to staff the machine’s full range of capabilities.

With the ERGOSA Universal Packer from Canadian manufacturer IMPACK, HEYNEN Kartonagenfabrik can up the production speed of its newest folder-gluer. The ERGOSA reliably processes a variety of different product types at high speed. Left to right: General Manager Joachim Gimpel-Henning, print shop and glue line manager Karl-Heinz Souvignier and IMPACK’s Stefan Badertscher.