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MiniTec not only offers conveyor components and lines, but also realises sophisticated material flow solutions, as the example of an industrial coffee roasting plant shows. Here, many food production guidelines had to be fulfilled and goods of different types and packaging had to be transported. The coffee products are transported quickly and safely over a length of 1.2 kilometres, across different levels, at high speed and very smoothly.
Coffee is by far the most popular drink in Germany. According to statistics, coffee lovers drink 146 litres per person per year. Many transport and production steps are necessary before the exotic bean ends up in the cup as a steaming drink. The roastery plays an important role here. It is a long way from the complex roasting process to the shop shelf.
Technical problems have to be solved and many regulations have to be observed that are stipulated by German food law and the IFS Food (International Featured Standards Food). The transport of coffee products within the roasting plants also needs to be well planned and professionally realised. Coffee varieties in different packaging must be transported from the filling plant to the packaging station.
Comprehensive requirements
At the request of a large German coffee roasting company, MiniTec developed a comprehensive material flow solution that perfectly met the diverse requirements. The fact that MiniTec has specialised in solutions for material flow and automation for many years and is ideally equipped for these issues with its GKF link chain conveyor system, the modular profile system and components such as spiral conveyors was an advantage here. A customised intralogistics solution was required to enable the transport of coffee cans and packaging bags between the filling line and carton packaging. Around 1.2 kilometres over various levels and high speed with very smooth running - these were just some of the requirements.
Conveyor line for the material flow.
MiniTec planned, developed and installed a customised material flow solution for a large roasting plant.
Well equipped with link chain conveyor system
With the flexible and energy-efficient GKF link chain conveyor system, MiniTec has created a system for such requirements that enables a wide range of solutions. Conveyor lengths of more than 1,000 metres with diverters, buffer sections and separators can be realised. Including the drives, the entire system has a modular design and offers standard solutions for every configuration. And like all products, this technology is also based on the proven MiniTec modular system: all components fit together perfectly for extensions, add-ons or any necessary safety equipment.
For example, the substructure, side guides, sensors, drip pans and attachments can be easily installed at any point and flexibly adapted to the conditions on site. The special requirements of the food or beverage industry as well as specifications for packaging lines. Cosmetics production, the pharmaceutical industry or mechanical engineering can be realised.
Complex conveying tasks
Within a short period of two months, the MiniTec technicians developed and manufactured a complete conveyor system for the coffee roasting plant, which is designed to transport coffee in cans (PAD cans) and in coffee bags (whole beans up to 1000 grams). The conveying capacity had to be very high in accordance with the production conditions and be up to 180 cans per minute on the workpiece carriers. The requirements for the infeed (20 metres per minute) and outfeed (40 metres per minute) were also high.
Safe travel over 1.2 kilometres
As soon as the coffee packaging starts its 1.2 kilometre journey from the filling station in the roasting plant, there are height differences to overcome and switches and distribution stations to pass, usually in a very confined space. This is where the design advantages of the GKF system, which is equipped with modular belt chains in track widths of 152 and 229 millimetres for use in the food industry, really come into their own.
The many standard components of the modular system, which enable the realisation of horizontal and vertical curves, are an advantage here. But also curve wheels for tight radii, flat top chains made of plastic or steel, roller, carrier and accumulation roller chains as well as various motors. And drives with frequency inverters are available for infinitely variable conveyor speeds.
Over hill and dale with a spiral conveyor
The local conditions posed a challenge for the material flow, as a large part of the conveyor system had to be installed under the hall ceiling at a height of three to five metres. Fire protection regulations also had to be taken into account. These required the conveyor lines to be routed through fire protection walls with fire protection doors and source bodies in confined spaces. Nine storage towers, each with a conveyor section of 50 metres, were integrated to ensure a constant material flow even at full load. The production halls of the roasting plant are criss-crossed by conveyor lines over several levels.
The requirements were very special: around 1.2 kilometres over different levels and a high pace with a very smooth run.
In addition to long distances, differences in height also need to be bridged. The WF 3000 spiral conveyor from MiniTec is an elegant and practical component for such applications. With this system, differences in conveying height of up to three metres can be bridged. However, the spiral conveyor also offers a second major advantage: it serves as a storage or buffer for conveyed goods on a very small footprint. On the conveyor section of up to 50 metres, with a space requirement of only around three square metres, such systems allow a constant material flow even at full capacity. Two electric motors are sufficient to operate the system, which has a positive impact on the energy balance.
State-of-the-art control technology is used to synchronise and tune the motors, which enables dynamic speed applications. The entire system is also trimmed for extremely low-noise operation thanks to design features and optimised slide rails. The use of high-quality components enables virtually maintenance-free operation, and the bowl feeder is also extremely resistant to contamination. In combination with the energy-saving motorisation, this ensures a high level of efficiency in production.
A large part of the conveyor system was installed under the hall ceiling at a height of three to five metres.
Reduced energy consumption
The client also required a high level of energy efficiency for the system. The MiniTec technicians were able to realise this with economical electric motors, demand-controlled speed regulation and line shutdowns when idling. In addition to MiniTec quality components, high-quality drives and control systems were also installed to achieve a high level of reliability. For the drive, 74 SEW drive motors with field distributor 7 and Profibus control are used, while a Siemens S7 Safety PLC with 180 inputs and outputs handles the control tasks.
Always in the right position
Another special feature arose during operation of the system: the coffee packets had to be placed in a defined position. Special feature: The packs had to be turned over with the base facing forwards, for which a deflector rail was initially used. However, because the cycle time was to be increased from 40 to 60 units per minute, this process was no longer suitable. The MiniTec technicians developed a ‘turning star’ for this purpose. This is a circular construction in which the coffee packets are turned forwards by turning blades. Before realisation, however, it was necessary to check whether this would also work in practice. Due to the high cycle speed in particular, we wanted to ensure that there would be no problems later on, for example that the packets would not get stuck or burst open.
A simulation solution was used for this, which enabled a digital test run. Based on the knowledge gained, various changes were made to the model system until it ran smoothly. For example, guide rails were installed so that the coffee packets stay on track and do not fall off the conveyor belt. The effort paid off: In the finished system, the process worked completely smoothly right from the start. Incidentally, this approach also reduced the overall lead time for the project.
Experience in material flow and automation
A conveyor system of this size not only requires precise planning, but the installation and fine-tuning of the production processes must also be carried out with the utmost care. This is where MiniTec customers benefit from the engineering team's many years of experience in automation and systems engineering in a wide range of industries. At the coffee roaster, the installation and commissioning was realised in just two months. Since then, the coffee products have been travelling down the line: With the required smooth running at high speed and absolutely reliably.
Do you need a suitable solution or an approach for your project? Then please contact us!