Ever shorter product life cycles, stricter hygiene requirements, especially for the food packaging industry, as well as increased labor costs are just a few of the many challenges that our customers - including SKY-LIGHT A/S - have to deal with.
SKY-LIGHT develops and optimizes packaging and films containing one of the highest proportions of recylced material on the market. For more than 50 years, SKY-LIGHT has been supplying demanding companies in the pharmaceutical and food industry across Europe with packaging products. SKY-LIGHT has been producing with sustainable materials like PET since the early 1980s and therefore has been using Kiefel machines since 1985.
Maximum consideration for the environment and a high and consistent quality for optimal product protection and perfect product presentation are very important to SKY-LIGHT.
|Machine type||KMD 78.2 Speed|
|Stacking||Pick & Place Inline|
|Automation||Kiefel Speed Automation|
|Goal||More output, lower labor costs, deep integration of automation in the machine|
For cheese packaging, the base and lid have to be produced fully automatically - hygienically, without contact with the operators, and then packed up to the ready-picked pallet.
"The geometry of the cheese base and lid can certainly be described as complex, so one of the challenges was to ensure reliable stacking with a minimum number of format parts," says Kiefel Packaging project manager Christian Burgstaller.
It was also important to note that the products in small cartons, including the inlay bag, had to be positioned precisely using grippers. It was important here that the robot gripper was precisely programmed so as not to damage the bag inside.
Likewise, a high number of cavities, a very high number of cycles and thus a high output had to be achieved.
In addition to the above requirements, it was also important to take the most space-saving approach possible, i.e. the required machine including integrated full automation should have the smallest possible footprint.
"A high degree of complexity presented the entire project team with challenges, but also led to great technical solutions!" says Christian Burgstaller.
Because SKY-LIGHT had not required a machine of this type or such advanced full automation up to that point in time. Since many requirements were identified during the course of the project, a high level of exchange and solution-oriented thinking and action were essential. "Kiefel assisted me with a lot of support here," says Jens Rohmann, project manager at SKY-LIGHT. "It wasn't easy to find solutions for all of the requirements, but we did it together. I'm very satisfied."
SKY-LIGHT opted for a complete turnkey solution from Kiefel: The proven steel rule machine SPEEDFORMER KMD 78.2 Speed, equipped with full “Kiefel Speed Automation” (KSA). According to Jens Rohmann, that was one of the decisive factors in the project: "We chose Kiefel because the automation is optimally integrated into the KMD.”
In the meantime, the KMD 78.2 Speed has not only been put into operation successfully, it is also running at the expected number of cycles and performance level. "We expect that we will be able to realize the planned amortization period, i.e. the planned return on investment will be achieved shortly," says Jens Rohmann. In addition, the KMD 78.2 incl. KSA is very easy to operate and maintain.
SKY-LIGHT also appreciates the minimal space requirements despite full automation. The company emphasizes the additional advantage of reduced labor costs and thus more efficiently workforce utilization, freeing up staff for other tasks.
After automated palletizing by Kiefel Speed Automation, the cheese packaging – consisting of a base and lid – is transported by truck to the customer in Germany. There, cheese bases and lids are separated. The bases are then automatically filled with the cheese or so called "cheese roulades" and closed with the lid. Last but not least, the final touch is added to the packaging in the form of an attractively designed printed label.
In this way, the packaged cheese can be transported from the factory to the supermarkets.
"In my opinion, Kiefel offers the best machines for production with PET, utilizing fully automated solutions," emphasizes Jens Rohmann.
Together a lot could be achieved in the project. Even when challenges were encountered, SKY-LIGHT could rely on the excellent cooperation and project management at Kiefel - a good solution was always found. “Kiefel gave me a lot of support in the day-to-day project business. Not only did they understand what we needed, they also looked for solutions and simply implemented them.”
Thank you SKY-LIGHT for the insights!
We look forward to implementing more successful projects together with you in the future!