Aylesbury, UK - Cartridge assembly at Derbyshire, UK-based 2K Polymer Systems Ltd (2KPS) has recently been upgraded with the help of specialists at Aylesbury Automation. Robotics and automation experts helped 2KPS to increase productivity and improve the quality in the assembly of CIC (capsule in cartridge) products for two-component chemical types.
Installation of the new equipment increased 2KPS's capacity, allowing it to meet rising demand, whilst eliminating the risk of repetitive strain injuries. An added bonus was that 2KPS saved valuable production floor space.
"We've been able to make significant reductions in the number of manual operations on this line whilst producing more product, at consistently high quality levels," said Stewart Riley, operations manager at 2KPS, in a 24 Aug statement from Aylesbury Automation.
2K Polymer Systems, based in Alfreton in Derbyshire, is automating its manufacturing processes as part of its aim to remain competitive in world markets from North America to Asia. As a leading supplier of two-part chemical anchors and grouts for the market for private-label products, 2KPS "requires extremely high quality manufacturing processes and controls," the statement said.
To package polyester and epoxy resins in a 2K CIC format involves filling 'capsules' containing the two chemical components in separate compartments, which are then inserted into rigid cartridges. Each assembly consists of the cartridge, a capsule of chemicals, a piston, a label and usually with one or two detachable mixing nozzles and a cap. This line caters for two sizes of cartridge -- 300 ml and 150 ml.
Production used to be extremely labour-intensive and repetitive, said Aylesbury Automation, which designed an automated process which would significantly reduce the number of manual operations in cartridge assembly. The final solution is two autonomous machines linked together and incorporating three DENSO robots supplied by Aylesbury Automation's robot division, AA Robotics.
"By understanding what we do, Aylesbury Automation has been able to devise an automation solution for us which not only increases our output per man hour, maintaining our competitive position in world markets, but also raises our quality standards and enables us to keep up with demand," said Riley.
2K Polymer Systems develops private label products for anchoring, sealing, bonding, filling and repair. It specialises in chemical mortars and resin-based compounds for performance-critical professional markets as well as for do-it-yourself repairs.