SKY-LIGHT, a film and packaging manufacturer, has invested in a new production plant that required an efficient and safe packaging system. The previous manual processes were not optimal in terms of the working environment and safety, and the new plant had to be able to handle rolls weighing between 200 kg and 1800 kg (441 lb. to 3968 lb.). This meant that the packaging system needed to be very flexible and capable of adjusting to nine different packing methods. SKY-LIGHT did not have the internal resources to develop this system, and so they contacted DIS/CREADIS to take over the development, construction, design, setup, assembly, and commissioning of the plant.
The development of the flexible packaging system was a challenging task that required machinery and engineering expertise. The system needed to be able to handle rolls of diameters and widths while maintaining safety, user-friendliness, and a positive working environment. The plant had to be able to operate 24/7, as any errors or downtime could result in significant losses. To develop a new system, SKY-LIGHT needed to partner with an experienced engineering service provider.
DIS/CREADIS conducted a pilot project with SKY-LIGHT, facilitating several rounds of workshops to generate viable solutions and ideas. DIS/CREADIS then conducted an analysis and developed concepts and ideas with ongoing evaluation and dialogue with SKY-LIGHT. The result was a semi-automatic, operator-controlled plant that was based on simple, reliable solutions. DIS/CREADIS developed a weighing, sorting, and packaging system that could handle different roll sizes in terms of diameter and width. The system was very flexible, with the option of adjusting for nine different packing methods.
DIS/CREADIS is experienced in developing machinery and building large-scale equipment. They worked closely with SKY-LIGHT, conducting workshops and analyses to ensure that the final product was tailored to SKY-LIGHT’s needs. The partnership resulted in a reliable and safe packaging process that significantly increased productivity and surpassed the benchmark in safety. SKY-LIGHT was impressed with DIS/CREADIS’s approach, referring to the plant as a stable, future-proof roll handling plant with a safe working environment.
“It was a project that started with a piece of blank paper and ended with a very flexible and stable packaging system that has run smoothly since day one, with a couple of small adjustments in the first few days, which is not very normal when setting up a new production plant. So, the preparatory work was done well. The plant is also several notches above the benchmark in terms of safety. It was clear that we were working with experienced consultants used to building large machinery,” says Claus Skovbo, Supervisor at SKY-LIGHT.
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