Innovative Modular System for Filter Production

Source from:  TJI 12/31/2013

In close cooperation with a leading manufacturer, CSi industries B.V. has developed an innovative, flexible storage and distribution system which automates the filter handling process.

The filter cigarette is the most widely sold cigarette around the world, and most cigarette manufacturers produce their own filters for their cigarette range.

Future product development is likely to focus on filter technology and in an industry that has already been excessively automated for many years, it is clear that a lot of manual work is still performed when producing and processing filters.

Filters are produced from the basic fibre material and manufactured in various lengths, depending on their final use. Until recently, filters with a length of approx. 120 mm were filled into plastic trays, in so called tray fillers (TF), lids were then fitted by the operator who then stacked each tray onto a pallet.

Once palletised, the filters were placed in storage racks to allow them to cure for a specified length of time. Following the curing process, the pallets were retrieved from storage and the trays manually de-palletised by the operator.

The tray lids were then removed by hand and placed on the in-feed section at the Tray Unloader.

This process requires the handling of empty trays at the Tray Filler and Tray Unloader, involving extremely labour intensive activities. Pallets also occupy valuable floor space and the entire process can lead to confusion, making tracking and tracing of products through the filter handling process difficult.

CSi's newly developed filter handling system allows for the Tray Fillers and Tray Unloaders to be connected directly to a Miniload storage and distribution system, eliminating all manual labour. Filters are now filled into compartment trays which have vertical partitions which keep the filters in line and accurately stacked in the tray. Filters are no longer blown through pipes to the production machine, but are transported on Mass Flow conveyors. The new central Miniload system now forms the link between filter and cigarette production and fulfils a multitude of functions.

An important feature of the system is that every module has a redundant Miniload crane situated in a holding area outside of the safety fencing. If required, the Miniload is able to take over the crane function and will be in operation within 10 minutes.

During the development of the system, CSi, together with the customer, attempted to define a standard module that is as compact as possible and that can be introduced into other factories.

This goal was successfully achieved, where a maximum of five Tray Fillers, five Filter Makers and twelve Tray Unloaders can be connected in a standard modular form. Acting as a system integrator, CSi used components from key partners in order to achieve the best solution.

Three modules are now in operation in two of the customer's factories, with the potential of implementing this system at another four to six locations around the world. This system could also be an interesting option for other major cigarette manufacturers, who are wrestling with the same issues

Information provided by CSi

Key data

-Sector: tobacco industry

-Countries: Germany, Russia

-Total automation of filter storage and distribution

-Standard module for 5 Tray Fillers and 12 Tray ?Unloaders

-Storage capacity per module: min. 9.760.000 filter rods ?(depending on the building height)

Handling capacity: simultaneously 7 trays/min of the Tray ?Fillers and 7 trays/min to the Tray Unloaders.

-Closed rack system with an option for integration with the sprinklers

Benefits

-Disconnection of filter and cigarette production

-Savings in staff costs and a significant increase in ?efficiency ?because of independent filter production

-Efficient use of floor surface, with high storage ?capacity

-Simple, proven and reliable technology

-Full Tracking & Tracing

Technical highlights

-Supply and removal of full and empty trays, in batches of 10 trays. Handling of smaller batches or just 1 tray at the end of a production run is also possible.

-Storage of trays in closed racks in order to guarantee the curing

time, where maximum use can be made of the available height in the ?building.

Fully flexible link between Tray Fillers and Tray Unloaders.

-100 per centTracking & Tracing by using RFID tags on the trays in ?combination with an integrated Warehouse Management System (WMS)

-Supply and removal and storage of filters coming from or to be ?delivered to third parties.

Innovation

-Fully automatic filter handling

-Modular system which can be used in many places

-Disconnection of filter and cigarette production

-In-built redundancy

-System integration by CSi

-Flexible use of filter production machines

-Automatic self cleaning