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Case Studies Of Industrial Robots

Robots in action can be found everywhere. Robot Manufacturers give examples of robot applications in different industries.

Wittmann, Austria - IFR-Partner

Packaging Success for Cebeci Plastik San.

Cebeci Plastik San. ve Tic. Ltd. Şti. was founded in 1968 as a small manufacturer and today is a leader in the packaging industry with annual volumes of 55-60 million containers per year. It currently occupies a production area of over 4,000 square meters with 12 machines ranging in tonnage from 80-220 tons and of which 6 are equipped with WITTMANN robots.

The packaging industry is well known for its competitiveness as measured by the output per hour and its stringent requirements for achieving the highest uptime. A very important part of their formula for success is ensuring that the take-out robot also provides the highest reliability and shortest possible removal time.

For the past 30 years Cebeci Plastik has built-up its reputation for its superior product and service quality in the Turkish plastics industry to become one of the countries biggest producers of plastic packaging. In the beginning the company specialized in the production of kitchen supplies and has since diversified into general food packaging including IML (In-Mold Labeling). Their growth continues today with a strong focus on the development of its product portfolio and by working without any compromise on its quality principles.

Alican Cebeci, owner and founder of Cebeci Plastik

Mr. Alican Cebeci, owner and founder of Cebeci Plastik San. ve Tic. Ltd. Şti. located in Istanbul, Turkey, discovered the ideal automation partner in WITTMANN BATTENFELD Plastik Makineleri Ltd., the Turkish subsidiary of the WITTMANN group. WITTMANN offers plastic processors a diverse range of robot systems ranging from top entry to SCARA type side entry robots and a complete line of standard linear side entry robots for the highest accelerations and decelerations.

In 2007 Cebeci Plastik decided to invest in automation systems and began a long-term comparison of three competitive robot brands looking at the following criteria:

  • ease-of-programming
  • in/out times
  • price
  • quality, and
  • service

The decision was made to award all future automation business to WITTMANN because of their outstanding product and service quality not to mention the other attributes noted above.

In addition to the basic and clearly obvious advantages provided by the WITTMANN robots, Cebeci Plastik has also experienced increased mold life as well as reduced maintenance costs. The elimination of free drop has resulted in less reject parts and therefore higher productivity, which in the end brings us back to their main objective of "Improving the output per hour."

When Mr. Cebeci was asked about his motivation for the move into automation systems and the benefits he indicated, "In the past we employed one operator per machine but now with the robots one operator can handle 3 machines. The return on our investment is typically about one year but never more than a year and a half maximum." Mr. Cebeci continues, "One of the most important issues in the food packaging industry is the hygiene. We have reached perfect results with the introduction of the robots and the minimization of human access to the production area. Another advantage of automation is the ability to count the parts which eliminates any short shipments to customers."

It should be noted that the counting of parts is an inherent feature of the WITTMANN robot control and offers several advantages. For example, the robot can be programmed to count the shot/parts placed/dropped into a box before indexing the conveyor. This offers much greater accuracy than having a second step where the operator weighs the entire box to obtain a rough estimate of the total number of parts. Instead of having too few or too many parts in a box, accurate counting guarantees the exact number of parts shipped.

Wittmann Robot at Cebeci plantOver the years Cebeci Plastik has invested in several WITTMANN robots including W711, W721 and W7X5 models. This horizontal robot with SCARA kinematics is designed for the shortest part removal times and combines the advantages of the rotational horizontal axes with a parallel end-of-arm tooling (EOAT) motion to simplify the operation and programming of entry into the molding area. A further advantage of this design is the minimum space requirement on the rear side of the molding machine. The cycle times of the robots are dependent on the size and cavitation of the parts but are as fast as 5.5 seconds.

The company had plans to move to a new, larger plant in 2009 with a further investment in approximately 25 more machines and robots. However, due to the current economic situation the project has been postponed until the economic environment returns to normal levels. In the meantime, Cebeci Plastik has equipped the molding machines with more equipment from WITTMANN like loaders and water flow regulators.

 

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