Fully automate your production environment

Significantly cut costs

Increase productivity and quality while minimising wastage

Integrate seamlessly with existing machinery

Achieve a prestigious, fully integrated, industry-first production line

Benefits

The complete automation of the process has enabled the customer to significantly cut costs in comparison to the previous, labour intensive, off-site manual operation. Mpac Langen delivered an innovative solution which gives the customer high productivity, consistent quality and minimal waste. The machine is integrated with other standard machinery to fully automate the customer’s production environment providing the customer with a prestigious, industry first production line.

  • Cost of sales reduction through elimination of manual assembly and associated shipping costs
  • Significant reduction in waste
  • Capacity to meet growth and market demand with a new and novel product.

 

Challenge

Veuve Clicquot Ponsardin (VCP) required a fully automated solution for the construction of a new, luxury presentation box. The famous champagne house wanted to create the first industrially produced, eco-friendly luxury packaging solution.

The Design Box is made up of two parts. The complex inner drawer (barquette) starts life as a flat blank and the outer sleeve (fourreaux) as a pre-glued skillet. VCP required the bottle to be inserted into the drawer at a specific orientation, with careful handling to ensure that no damage occurs on the bottle or label during the process. Following this, assembly of the inner drawer into the outer sleeve was required to complete the final pack.

  • Design and develop a high-speed, fully automated line for carton erection, bottle insertion and closing of a famous drinks brand.
  • 8000 bottles per hour
  • Eliminate cost and limitation of previous hand assembly

Solution

Creating a fully automated process required an innovative approach, and the expertise to integrate complex custom machinery with standard solutions. We worked with VCP and Design Box converter SCA Packaging, assisting in product design to optimise the carton blanks for automatic handling. Sustainability and environmental impact were important factors for the customer in the creation of the new presentation box and this was followed through in the design of the packaging process.

Two Fanuc robots start the fully automated process by loading stacks of the flat blanks directly from the pallet into magazines. The robots are also utilised to manage waste packaging recovery for recycling. To construct the inner drawer, a bespoke multi-station rotary turret was designed. Erecting such a complex, multi-folded drawer from a very large flat blank required us to draw upon our vast product handling experience and the result represents a milestone in box forming technology.

Transferring the inner drawer to the bottling turret presented some further challenges. Mpac Langen delivered a transfer station capable of changing both the pitch and the orientation of the drawer, so that it was ready to receive the bottle. Furthermore, as conventional methods may have damaged the labeling or bottle, a special star-wheel arrangement was used to feed the high-value bottles of champagne into the process. In-process inspection was also provided. The special purpose machinery was then integrated with a ‘Chinook’ side load cartoning machine. This machine erects the outer sleeve and pushes the boxed bottle inside to complete the assembly of the Design Box.

  • Continuous motion, rotary turret-based machine
  • Fully automated, robotic blank handling, replenishment and waste recovery
  • 100% product quality inspection
    • Bottle orientation
    • Assembly integrity
  • Fast-track delivery of machine:  14 months from initial enquiry to FAT

Interested in understanding how we tackle complex challenges like these?

Call us on: +44(0)24 7642 1100