In summary there were 3 reasons:
- Eliminate waste material from the final product
- Eliminate waste carryover to reduce machine maintenance interruptions
- Keep sensors clear to ensure consistent readings
Saica had issues with waste material build up in their existing system, resulting in blockages preventing continuous machine operation, as well as sensor interference, meaning disruption to business.
When we started working with the client, we noted that their existing system manages cardboard at various stages – for example, cutting cardboard in the die cutter, then moving it to the stripping section. At points the waste cardboard was removed automatically, for example after the stipping section the machine shakes the cardboard profiles to remove waste material.
However, their system for waste removal was not 100% effective, meaning that some waste was still passing through into the next section of the BOBST machine, causing a build up. Ultimately, this meant that the client had had to stop production, whilst an operative manually cleaned the inside of the machine. This was both time consuming as well as hugely disruptive to production.
In addition, the client wanted to add individual nozzles to deflect waste away from 8 photocell sensors within the machine. Colleagues from another site in the UK had made the client aware that these sensors were vulnerable to waste material blocking their view, and so could affect machine performance by signalling false alarms.