Automatic bonding of packaging for Bematech
Bematech is a leading European manufacturer of interior shading technology, boasting more than 28 years of tradition in the industry. The company is known for its innovative technology and focus on its own research and development, which enables it to create products that meet the growing demands for design, quality and functionality.
In 2021, it decided to modernise and streamline the process of packaging its products. Until then, these had been glued using a manual hot melt applicator gun with sticks and adhesive tape. "We wanted to improve the protection of products during transport and make the entire packaging process more efficient. Our products are often atypical in shape, fragile and require a specific approach" describes Karolina Mullie, CEO of Bematech.
The start of the cooperation: Finding the right solution
The project began with detailed market research, during which Bematech focused on selecting a supplier that would meet high demands for quality, reliability and efficiency. As part of this process, they chose Kaletech, the exclusive representative of Robatech technology for the Czech Republic. Robatech technology was already well known and used at that time in other operations and companies with which Bematech cooperated. Based on good references and an analysis of total costs, they decided on this path.
Design and customisation of the solution
The product that was the subject of this project is packaging made of multi-layer paperboard, used to pack interior shading technology products. The main goal was to find a technology that could effectively automate the entire packaging process while ensuring the strength and precision of the bonded joints.
Bematech chose Inprotec as the supplier of the entire line. Kaletech entered the process during the technology design and line setup. "They helped us select the right adhesive, set up the system according to real operation and always responded quickly and helpfully" Karolina Mullie describes the cooperation.
The line has 2 workstations, each with a sliding carriage with a fixed head and a manual applicator for any additional joint bonding. The adhesive is applied in the form of intermittent application. "For this situation, we chose the Vision S Pro melter with four heated hoses, SX 1S application heads and EasyStar manual applicators as the optimal technology", describes Milan Milian, project manager at Kaletech. "This solution reliably meets the requirements of both workstations" he adds.
Technological challenges
The project had several key challenges that had to be solved. Among the biggest technological problems were the above-standard distance between the melter and the applicator (12-metre hose length), setting the angle of the application head relative to the material and optimising the movement speed of the carriage with the application head. These aspects were crucial for achieving even adhesive application and the required joint strength.
It was also necessary to choose the right adhesive with a sufficiently short open time so that the boxes could be handled quickly. After several tests, the low-temperature hot melt adhesive KALEP MC 1400 was finally chosen. It met the quality requirements for the bonded joint and, in addition, brought a pleasant bonus in the form of greater environmental friendliness of the bonding.
Integration of the new system into production
After selecting the technology, integration into the existing production process began. Bematech, together with the integrator Inprotec, gradually implemented the new packaging system. Since this was a new technology, the process of commissioning the line was not immediate. It took several weeks to tune and optimise the entire system to ensure maximum comfort for the operators while achieving the required efficiency.
The products being packaged had various dimensions, which required precise setting of the parameters for the cardboard die-cut. "When tuning the line, we focused on the correct setting of all these factors, which was essential to ensure smooth and trouble-free operation," adds Milian.
The first results and benefits of implementation
After the introduction of the new packaging system, there was a significant improvement in all areas that were key for Bematech. The main advantages are:
- Packaging speed: The overall packaging process is significantly faster than the previous method, which allows for faster order handling.
- Increased safety: By minimising manual contact with hot melt adhesive, higher safety is ensured, in particular by reducing the risk of burns.
- Environmental benefit: The new technology enables lower consumption of adhesive and packaging material, which can be recycled and used as filler. This has a positive impact on the environment.
- Benefit for staff: professional bonding brings better ergonomics and less physical demand for the often female staff in this section of production
- Quality and strength of joints: The joints are strong, clean and retain their strength even after a long time, which contributes to reducing complaints and damage to products during transport.
- Economic benefit: All the points mentioned above have a favourable impact on the economic side
Next steps and the future of the project
Today, several months after the implementation of the new technology, the line operates reliably and brings the benefits that Bematech had hoped for. "Regular service and training for operators are currently underway to ensure smooth production with high quality" summarises Milan Milian on the current situation. Bematech continues to work on further automation of production processes and the use of artificial intelligence in these processes as well.
Customer satisfaction
Karolina Mullie summarised her experience of the cooperation with Kaletech as follows: "Cooperation with Kaletech has been at a very good level. We particularly appreciate their approach – they tried to understand our operation and not to be just a technology supplier. The bonding system from Robatech is reliable, precise and has overall helped us significantly streamline packaging. The joints are strong, clean, and hold without any problem even after a long time. Overall, we have a good feeling about the cooperation – it turned out to be the right choice".
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