Case study Automatic Container Unloading Logistics

 

Unique collaboration between Cartonmover and Qimarox

OMS saves manpower and improves health with Automatic Container Unloading 

OMS International saves costs by automating the unloading of containers. The logistics service provider from Oosterhout has installed a unique solution from Cartonmover in close cooperation with Qimarox for this purpose. With this solution, boxes are unloaded at high speed and automatically stacked on pallets. The key to success is the unique pattern generator from Qimarox that automatically generates stacking patterns and translates them into instructions for the palletizer.

Unloading containers is physically demanding work. Employees must bend deeply, reach high and constantly twist their bodies to pick up the often large and heavy boxes one by one and lift them onto a telescoping conveyor. More and more retailers and wholesalers who import their goods are looking for solutions that make the work more bearable. A large proportion of them end up with Cartonmover, the company that eight years ago brought the first semi-automatic solution for unloading shipping containers onto the market.

Unburdening employees

One of these companies is OMS International, which unloads about a hundred containers of non-food items every day for one of the largest supermarket chains. The logistics service provider from Oosterhout was looking for a solution to relieve the two hundred employees from Eastern Europe. Via the Internet, Jaroslaw Wiecha, operational director of OMS, stumbled upon Cartonmover. After a one-month test period, he was convinced of the usefulness and efficiency of the most popular model: the ERGO.

The Cartonmover Ergo is a mobile machine with a 900 mm wide conveyor belt and a 2000 mm wide platform that can move up and down. Employees therefore no longer have to stand on the bottom boxes to pick up the top boxes. Because the telescopic belt can be lowered to 30 centimeters from the bottom, they hardly have to lift the bottom boxes anymore. This leads to considerably less  physical complaints. Anyone can therefore start working with this machine immediately and process up to 1800 boxes per hour. There is a good reason why this machine is used in almost all of Amazon's European distribution centers.

Automatic palletizing of boxes

However, the Cartonmover Ergo only solves part of the problem. The boxes that, thanks to this machine, are unloaded out of the container with much less effort and at a higher speed, still have to be stacked on pallets: a manual and labor-intensive job that until now also led to many physical complaints. "That is why we started looking together with OMS for an additional solution for palletizing boxes. We have seen several palletizers and palletizing robots in practice," says Wiecha together with Tony Groters of Cartonmover.

The choice finally fell on the Highrunner HR9 from Qimarox. This palletizer offers more capacity than a palletizing robot, more than enough to handle the flow of boxes from the Cartonmover. An additional advantage is that, unlike a robot, the boxes are carried at the bottom, which limits the risk of product damage. Qimarox's special stacking method also ensures better stacked pallets. "With the people from Qimarox we immediately had a click. Unlike other suppliers, they were prepared to modify the design of the standard machine, enabling us to increase capacity by another 25 percent," says the warehouse management team at OMS.

New: Qimarox Pattern Generator

The decisive factor in choosing the Qimarox palletizer is the new pattern generator. This is particularly important when unloading containers. For each new container, the box size must first be determined and then a new stacking pattern must be created. "Manually measuring boxes and programming stacking patterns is a time-consuming task. The cost of this does not outweigh the benefits of automatic palletizing.".

The pattern generator developed by Qimarox works fully automatically. The employee only has to place the first three boxes in a 3D scanner to determine the dimensions. The underlying software automatically calculates the average box size including tolerances. Is the box size already in memory? Then the corresponding stacking pattern is called up. Is the box size not yet known? Then the software generates a number of new stacking patterns, from which the employee can select one. After the selection the pattern is automatically translated into instructions for the machine."

70 percent of box sizes

OMS is the first company to apply the pattern generator. An extensive test preceded this. Cartonmover first sent a file of 8,000 box sizes from OMS to Qimarox, 70 percent of which could be stacked automatically with the help of the pattern generator. "Then we sent a few test pallets with various box formats to Qimarox's demo center in Harderwijk. These could indeed be processed without any problems. That was enough proof to put the pattern generator into operation," Wiecha and Groters explain.

The Qimarox Highrunner HR9 is installed at a fixed location in the OMS International warehouse. The cartons are fed via roller conveyors and chain conveyors from Roltrax, which also supplied the integrated pallet wrapper and empty pallet buffer station. Flexible harmonica conveyors from Cartonmover connect this static setup with the mobile Cartonmover ERGO. The cabling, control and site management is in the hands of DH Automation. "All machines are built in the Netherlands. The entire system was installed on time according to plan." says Groters, who acted as the main contractor with his company Cartonmover.

24 hours a day, 5 days a week

Meanwhile, the Cartonmover Ergo in combination with the Qimarox Highrunner HR9 runs no less than 24 hours a day, 5 days a week. OMS is now able to process 10,000 cartons per day. Groters: "Originally, the Cartonmover ERGO was designed to serve three docks. By supplying additional flexible conveyors, OMS is able to deploy the machine at four docks, enabling the company to work through the night without having to move containers. The entire system has been running successfully for over a year now and has saved several FTEs. Partly because of this, the Return on Investment period is short."

Innovative palletisers and vertical transport systems at the PackExpo East 2015

Qimarox delivers speed, flexibility and durability at a competitive price

Qimarox is taking the world by storm with its wide range of palletising and vertical transport systems. Qimarox’s innovative product lifts, pallet lifts and palletisers are proof that high capacity and flexibility can go together with low operating costs and a high degree of durability. Qimarox will be present at the PackExpo East 2015

Qimarox supplies components for material handling and packaging systems that are characterised by a compact and modular design and high degree of standardisation. Consequently, the cost of purchase, installation, integration, use and maintenance is reduced to a minimum, which makes Qimarox components the most competitive solutions in the market. At the same time, the components excel not only in capacity, but also in versatility and flexibility, which makes them easy to integrate into any situation. In short, Qimarox places mechanisation and automation of packaging processes and logistics processes within everyone’s reach.

Fast and efficient palletising

Qimarox’s Highrunner mk7 is an innovative palletiser that combines the capacity of a conventional palletiser with the flexibility of a palletising robot. Whether it’s boxes with or without covers, trays with or without foil, buckets, crates or jerrycans – the Highrunner mk7 can carefully and accurately position them into any desired pattern and deposit them on the pallet layer by layer. The user-friendly touch screen allows operators to easily select the desired stacking pattern and program new stacking patterns if necessary.

The Highrunner mk7 distinguishes itself in the market with its patented pattern-formation conveyor, which is always located at the same height as the top of the pallet. This allows the layers created on the pattern-formation conveyor to be deposited at lighting speed, which makes for a particularly high capacity. A built-in pallet lift ensures that the pallet drops automatically so that the next layer can be deposited after each layer is deposited. Once a pallet is full, the lift descends to floor level, after which a roller conveyor removes the products.

Integrating multiple Highrunners according to the unique Crossrunner principle results in an extremely compact setup where a single roller conveyor is sufficient for the supply and removal of all pallets, both full and empty. This results in a setup that is able to process large volumes while occupying little space.

Vertical transport and sorting

The Prorunner mk5 is the undisputed eye-catcher at the fair. This elegant product lift works according to the time-honoured paternoster principle, which results in a versatile vertical transport system with a capacity of 2,000 products per hour. Because a single elevator system can be used for both upward and downward product flows, the Prorunner mk5 is ideal for vertical sorting. The standard model of this maintenance friendly and sophisticated product elevator is available for the fixed price of only €6,950, including infeed and outfeed conveyors and safety fencing.

Unlike other continuous product elevators, the Prorunner mk5 can feed products in and out in three directions, without the need for additional equipment. Whether it’s boxes, crates, trays or bags: this clever product elevator transports them all to any desired level and without any critical product transitions. All products are transported horizontally at all times, so that product deformations are excluded.

The Prorunner mk5 has a patented drive system that reduces friction, therefore reducing energy consumption. Because the system keeps itself in balance, the motor only has to propel the product to be transported, and not the product carrier. The system can therefore be operated at a low motor capacity, resulting in considerable savings when compared to other lift systems. Partly for these reasons, Qimarox’s Prorunner product conveyors are used by many OEMs, system integrators and manufacturers of transport systems in various industries around the world.

Robust and compact pallet lift

The Prorunner mk10 – an extremely robust product elevator for pallets of up to 2,000 kg – is the latest product in Qimarox’s range of material handling systems. This product lift can transport up to sixty pallets per hour ten metres upwards. This standardised, modular product lift can be integrated into any end-of-line packaging system or storage system and can furthermore be used in conjunction with the Highrunner mk7, Qimarox’s unique product palletiser.

The Qimarox Prorunner mk10 is based on the design of the successful Prorunner mk9 pallet lift. The most important difference is that the new Prorunner mk10 features four instead of two columns, allowing it to easily transport pallets weighing up to 2,000 kg. The Prorunner mk10 can easily bridge any difference in height between 0.40 and 10 metres. Even at the maximum height difference of 10 metres, the lift can still easily transport sixty pallets per hour with ease. The Prorunner mk10 is equipped with a lifting platform of 1200 x 1200 mm as standard, so that it can handle not only euro pallets, but also product carriers of different sizes such as block pallets.

Thanks to its four-column construction, pallets can be fed in and out on four different sides. It is also possible to use a single machine to supply multiple infeed or outfeed conveyors, so that the lift can also be used for, for example, vertical sorting. Because the lift is constructed out of standard sections, its height can be increased in 250 mm increments. The Prorunner mk10 is constructed using steel instead of aluminium columns, which ensures great stability despite the dynamic forces that occur during operation. Lifting is silent in the Prorunner mk10 because it is taken care of by steel cables in a durable plastic case. Furthermore, unlike when using chains, the steel cables don’t require lubricating or tightening.

More information? Visit our stand

Want to learn more about our products? Visit us at the PackExpo East 2015. We would love to show you what makes our palletisers and vertical transport systems so unique. You can also learn more about our other products, such as our Securyfence screening system. For more information, please visit our website at www.qimarox.com.

Qimarox sponsors Harderwijk windmill ‘De Hoop’

Qimarox will sponsor the Harderwijk windmill ‘De Hoop’ for the next three years. This tower mill in the Vissershaven is one of the most striking features of Harderwijk’s historic city centre. With the sponsorship, the manufacturer of components for material handling systems demonstrates its commitment to social responsibility and the local community. 

The Netherlands is world renowned for its windmills. Particularly in the Golden Age, thousands of windmills (many with innovative drive systems) helped the Dutch economy to flourish. As a Harderwijk company, known across the globe for its innovative, patented technology, Quimarox would like to help preserve this Dutch industrial heritage.

‘De Hoop’ is a gristmill that was completely rebuilt in the Vissershaven in Harderwijk, after the old mill was destroyed by a raging fire in 1998. The mill, which is a nationally listed building, is open every Saturday and on other days during the summer. In the mill, the public can learn about the history of the mill and the work of the miller. Thanks to a team of around thirty volunteers, ‘De Hoop’ is operated regularly and mills at set times. Partly thanks to the financial contribution of Qimarox, Harderwijkse Molenstichting (the Harderwijk windmill foundation) will be able to continue to maintain and operate the mill in the future.

Qimarox and Harderwijk

Qimarox emerged from Nedpack in 2012, which was set up by Pieter Hannessen in 1995 in Harderwijk. The company develops and builds innovative machines that are used across the globe in end-of-line packaging systems and material handling systems, such as product elevators and palletisers. Qimarox’s machines are used in the factories of companies such as FrieslandCampina, Danone, Solvay, Nutricia, Staples, Unilever, Heinz and Procter & Gamble.

Qimarox is proud of its connection with the historic Hanseatic fortified city of Harderwijk. Every year, many of Qimarox’s international clients travel to Harderwijk to visit the test and demonstration centre at the Lorentz II industrial estate. Sponsoring ‘De Hoop’ means Qimarox can take the clients to see the historic town of Harderwijk and give them a guided tour of the mill, while offering them a typical Dutch souvenir.

About Qimarox

Qimarox is a leading manufacturer of components for material handling systems characterised by ruggedness and reliability. Innovative concepts, patented technologies and continuous development allow Qimarox (which emerged from Nedpack) to manufacture product lifts and palletisers that combine flexibility and productivity with a low total cost of ownership. System integrators and original equipment manufacturers from across the globe use the machinery of Qimarox in end-of-line systems and storage and order picking systems in various industries. Please visit www.qimarox.com for more information.

Fast, flexible and cost-effective standard palletiser

Qimarox introduces the Highrunner mk7

The Qimarox Highrunner mk7 is a palletiser that is not only lighting quick, but also very flexible. Because the machine is constructed entirely out of standard modules, the Highrunner mk7 can be used in any situation without any additional adjustments. Thanks to its high degree of standardisation, costs relating to purchase, installation, use and maintenance are also considerably reduced. This palletiser module is already available from €29,000. Furthermore, integrators can choose to add their own pallet lift, or use one of the Qimarox models.

The Highrunner mk7 is the result of continuous development by Qimarox. The design of the existing Highrunners has been further simplified, resulting in fewer parts and more standard components. As a result, costs relating to purchase, installation, use and maintenance are considerably reduced. All this makes the Highrunner mk7 the most competitive palletising solution on the market today.

Whether it’s boxes with or without covers, trays with or without foil, buckets, crates or jerrycans – the Highrunner mk7 can carefully and accurately position them according to any desired pattern and deposit them on the pallet layer by layer. The user-friendly touch screen allows operators to easily select the desired stacking pattern and program new stacking patterns if necessary.

The fastest in the Qimarox range

The Highrunner mk7 is not only economical and versatile, but also the fastest palletiser from the Qimarox product range. A unique feature is that the pattern-formation conveyor is always located at the same height as the top of the pallet. This allows the layers created on the pattern-formation conveyor to be deposited at lighting speed, which makes for a particularly high capacity.

This high capacity is therefore the result of the high position of the pattern-formation conveyor and the built-in lift supporting the pallet. After each deposited layer, the lift drops a little bit, so that the top of the pallet is always at the same height.

Once a pallet is full, the lift descends to floor level, after which a roller conveyor removes the products. At the same time, an empty pallet is supplied from the opposite direction.

Dual infeed system 

Because the machine is constructed out of standard components, the Highrunner mk7 can be used in any situation without any additional adjustments. By default, the machine features side infeed, allowing products to be supplied left or right of the pattern-formation location.

Companies that require higher capacities can choose a dual infeed system, in which two supply conveyors and a pattern-formation conveyor combine to provide an even higher capacity.

Qimarox also has easy to integrate standard modules for turning products, placing sheets between pallet layers, and wrapping pallets.

Installation by certified partners

Like the other Qimarox palletisers, the Highrunner mk7 is installed and integrated by certified system partners across the globe. That is, end users can count on having a partner who knows the machines and their capabilities inside out, so that a successful implementation is guaranteed.

About Qimarox

Qimarox is a leading manufacturer of components for material handling systems that are characterised by robustness and reliability. Innovative concepts, patented technologies and continuous development allow Qimarox (which emerged from Nedpack) to manufacture product elevators and palletisers that combine flexibility and productivity with a low total cost of ownership. System integrators and original equipment manufacturers from across the globe use the machinery of Qimarox in end-of-line systems and storage and order picking systems in various industries. Please visit www.qimarox.com for more information.