Content · 2019. 11. 6. · Content Presentation of Technica Family business Company profile End to end solutions Innovative solutions Light weight bottle storage solutions Multi-product

Content

Presentation of Technica

Family business

Company profile

End to end solutions

Innovative solutions

Light weight bottle storage solutions

Multi-product packaging solutions

Pallet inspection solutions

Auto truck loading solutions (single cases)

IOT

INNOVATIONS in Packaging Solutions

1982 Foundation of Technica as a local family business. Workshop: 76mas a local family business.

Staff: 4 Market: Local 2018 Technica has become a company with global reach. Factory Built Area: 7,500m Land Area: 15,000m Offices area 1,500m Staff: 200 Market: 36 Countries Branches: 6

Growth story

Technica a family business



His excellency, the President of the republic of Lebanon, General Michel Sleiman, delivering the LEA award to Technica GM, Tony Haddad in 2010 & 2013. This is administered by the European community to companies meeting European excellence standards.

Technica was recognized with the 1st runner up prize for the GHWP Award in London. We used this award as a platform to refine and improve our system, and to spread the concepts of the GHWP in our community.

GHWP Award 2013 Top 500 growth 2012 Lea Award 2010/2013 GHWP Award 2014

Technica was recognized for the second time with the 1st runner up prize for the GHWP Award in Shanghai.

Technica was selected as one of the fastest growing companies in the Middle East. Ranked 7th in Lebanon.

Technica was recognized with

Top 500 growth 2012

Technica was recognized for the Technica was selected as one of

High Merit Award 2004

Technica received the innovation award from the Association of Lebanese Industrialists.

Awards


Creating Shared Value


We installed solar panels to generate clean electricity (70KW).

We plant trees for our customers, 1700 trees planted so far in 3 years.

We recycle all our materials. We donated the waste sorting station to the municipality of Bikfaya.



Creation of “Technica Academy” - Grow & share the knowledge. - Develop highly skilled and competent technicians and engineers to follow the technological

breakthrough. - Develop career plan for the team.

Technica Academy


Technica company profile

Headquarters & main manufacturing facility: Bikfaya, Lebanon

Manufacturing & service center for EU - Warsaw, Poland (2019)

Branches: Jeddah, Riyadh, Dubai, Stockholm, Cairo & Lagos

Local partners: Peru, Russia, South Africa, Pakistan, Bangladesh, South Korea & India Countries with executed projects

Technica in the world



Key customers - Beverages

Key customers - Dairies

Key customers - water

Key customers - Food sector

Key customers - Petrochemical/Plastic

Key customers - Glass & Paper

Multinational customers

Our key customers



Metal plate making factory Laser cutting machine for plate (Bystronic) CNC shears CNC bending machines Area: 1,000 m2

Metal plate division



Components manufacturing factory CNC machines for turning, milling. Area: 1,000 m2

Components manufacturing division



Second machine assembly area 65m long x 40m wide. Area: 2,600m

Mechanical assembly division



Customer service division Customer oriented team - Installations - Maintenance & troubleshooting - Spare parts service

Customer service division


Technica end to end solutions

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Complete lines for food & beverage Automation equipment • Empty bottles handling • Conveyors • Accumulation systems • Packers • Palletizers • Mixed Pallets • Truck loading Electrical solutions • Inspection systems • Scada systems • IIOT Robotic solutions Warehouse automation Partners ABB Accraply Amtech Ancra Baumer Gernep Kuka Lanfranchi Robopac Rockwell Siemens



Industry 4.0: • Use of smart sensors and advanced analytics to predict needed maintenance • Reduce unplanned downtime • Anomalies can be quickly detected and fixed • Maintenance schedules can be optimized to minimize disruption

IIOT Internet of things: Features: • Real time connectivity through cloud • Full visibility on running systems all over the world

Complete lines for food & beverage Automation equipments • Empty bottles handling • Conveyors • Accumulation systems • Packers • Palletizers • Mixed Pallets • Truck loading Robotic solutions Warehouse automation Partners ABB Amtec Ancra Baumer Gernep Graham Kuka Lanfranchi Rockwell Siemens

Electrical solutions• Inspection systems • Scada systems • IIOT


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Complete lines for crate systems Automation equipment • Crate depalletizers • Crate inspection • Crate distribution • Crate packers • Crate palletizer • Pallet inspection • Pallet distribution Partners ABB KUKA PlasticBand Rockwell Siemens Unitech washers

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Light Weight Bottle Storage System

• SILOs & Unscramblers: - SILOs create top load on bottle requiring heavier bottle weight - Extract system from the SILOs and unscramblers leave scratches on the bottles - Big volumes, with limited number of SKUs

Deficiencies of common bottle storage solutions (between blowing and filling)

• Bagging/debagging: - Require plastic bags which increases cost and create environmental problems - Limited stacking height


The Need


Bottles are stored in stackable trays to achieve the following: • Compensate the difference in capacities between blow

moulder and filler • Create a buffer to prevent the stoppage of the blow

molder which increases the OEE • Overcome the disadvantages of common storage

solutions: - Zero pressure on bottles - No scratches - Greater feasibility with multiple SKUs

Technica’s Light Weight Bottle Storage System


The Solution


Bottles are palletized in stackable trays at the discharge of the blower, to achieve the following: • Preserving their orientation.

• Trays take the stacking load - Zero load on bottles.

• Trays and pallets are nestable - allowing multilevel storage.

• After storage, pallets are fed to a de-palletizer where the

bottles are transferred from trays to the production line - Keeping their original orientation.

• Empty trays are circulated back to bottles palletizing cell.

Operation Process


The Concept Buffer Storage

• Conveyor system allows in-line operation blower to filler, when no storage is required

In-line Operation

Features Bottles keep their orientation

Zero load on bottles

Modular storage for different SKUs

Smooth handling of bottles

Traceability of bottles inside the trays

High stacking possibility and organized pattern



Features & Benefits Benefits No orientor required

Bottle weight can be reduced

Flexibility of multiple SKUs on the line

No scratches

Possibility of FIFO, data report and analysis

Small footprint in warehouses


Savings • Main savings are generated by the reduction of

the bottle weight.

• Payback Period can reach less than a year.

Standard 2L bottle: 40g

LWBSS reduced weight: 34g


Savings & ROI

Multiproduct Packaging

• Market trend is driving towards multiproduct packages.

• Mixed distribution centers, need to ship different SKUs

on the same pallet, as per preorder from market.

• High volumes are required in a limited time, in order to

have a short window to “Go to Market”.

• Manual mixing operation is slow and requires a high

number of labor.

• Errors and miscounts are frequent.

• The need of large space for the operation, especially for

high variety of SKUs & high capacity.

• Difficulty to track the preorder and to generate output

reports

The Need

The Problem



• Automated system for mixing of various SKUs in

the secondary pack.

• Automated system for mixing various secondary

packages on one pallet.

• Savings in man-power and cost.

• Reduced space occupied.

• 100% error-free operation.

• High capacity, allowing very short “Go to Market” time.

• Squared and well-shaped pallets.

• System is connected to ERP, to receive preorders, and

generate production reports.

• IIOT platform on the cloud for online data collection and

remote analysis & storage of date

Solutions

Benefits



Operation • 3 pallets in-feed for 3 different SKUs. • Delayering of SKUs on 3 tasks. • Single line each SKU. • Inspect, code and print on SKU. • Mix 3 SKUs in a single secondary pack. • Palletize the mixed pack.

Capacity • Up to 200 secondary packs/minute. • Man power: 1 forklift operator to transport pallet.

Reference System being developed for Danone Holland

The Concept (Tray Mixing)



Operation

Capacity

Reference


The Concept (Pallet Mixing)

Reference System installed in Pepsi Jordan, in 2016.


Operation • 5 pallets in-feed for 5 different SKUs. • Picking of full layer from pallet. • Palletizing the layer on the mixed pallet. • Stretch wrapping the mixed pallet. • Pallet composition received online from provider

via ERP system.

Capacity • 4 layers/minute. • Up to 40 pallets/hour, depending on mix. • Man power needed: 1 forklift operator.

Pallet Mixing Line (Pepsi-Cola)


Pallet Inspection System

• Stop the line & reduce OEE

• May cause serious accidents

• Generate losses

• Cause quality problems

Defective pallets must be removed from operation


The Need

Defective pallets

The Solution

• Highly customizable sorting criteria

• Wide range of supported pallets (types & sizes)

• Operation speed up to 375 pallets/hour

• Inline operation for single line

• Offline operation for the whole factory

Technica’s Pallet Inspection System



Checks the integrity, geometry and structural stability of your pallets


The Concept (wooden pallet)

• Remove of any loose debris to allow accurate inspection.

• Ensure bottom runners will not jam on the line.

• Crush down protruding nails without rejecting pallet.

• Check for missing planks, to ensure product stability.

• Measure by laser that length and width are within tolerance.

• Apply load to test carrying capacity.

Wooden Pallet Inspection



• Detect missing legs and connection ribs by a series of rollers.

• Detect fragile bands and legs by forcibly deforming them and

measuring deformation by laser beam.

• Two laser scanners, one from the top and one from the bottom,

generate a 3D cloud image of the pallet detecting the presence

or absence of objects as small as a rolling dice.

• Transducers to detect the deformation of the top ribs

Plastic Pallet Inspection


The Concept (plastic pallet)

Mandatory for Warehouse automation:

• To run with LGV/AGV.

• To fit in the racking/storage system without getting

stuck or damaged.

Improved quality/safety: • Sustained quality for products on the market.

• Image and appearances of product.

• Minimize product damage due to damaged pallets.

• Eliminate safety hazards.

Increased OEE: • Fewer stoppages to remove defective products.

• Less jams on the lines.

• Reduced maintenance and breakages.


The Benefits



• Can be installed inline with palletizer line

Offline Automated System


Destacker

Inspection of pallet

Good pallet stacker

Defective pallet stacker

In-line System

• Fully automated system, can be installed for the entire factory.

• Stack of empty pallets are fed to system.

• Pallets are destacked and fed to the line.

• System checks the pallet for defects.

• Defected pallets are rejected on a separate line.

• Good pallets and rejected pallets are stacked in separate stacks.

offline System


ROI


Sources of savings are generated by eliminating:

• Damaged finished products due to fallouts.

• Stoppage time of line to remove fallen products.

• Maintenance & repair costs due to breakages.

• Work accidents..

Payback can be less than a year, depending on volume and on

quality of available pallets.

Automatic Truck Loading with Loose Packages

• Loading with full pallets:

- Low vehicle fill rate (75%)

Deficiencies of common truck loading methods


The Challenge

• Loading with loose packages:

- Loading with loose packages:

- Slow operation (4h to load one truck)

- Manual process, labor intensive

- No traceability of product / control of load

- Ergonomic problems for heavy loads

Automatic truck loading with loose packages to capture all these benefits:

• No operators needed

• Vehicle Fill Rate up to 95%

• Filling time less than 50min per container

• Flexible to accommodate any type of packages

• System can work for loading or unloading containers

Technica’s Truck Loading Solution (Patent Pending)


The Solution



The Concept


Instead of loading single packages one by one into the container, our system

loads a complete row of packages

System has two operational modes, loading and unloading.

A tailored solution to address all the truck loading gaps

The Loading Cycle


• The load order is read through ERP

• Loading algorithm generates a pattern with the maximum fill rate

of the load order. Constraints can be added to have heavy loads

at bottom and in the front of the container

AI Software

at bottom and in the front of the container

AI Software

• Packages are de-palletized from the pallets and single lined on

branch conveyors

De-palletizing

• Packages are merged into the main line according to the

required sequence by the pattern

Load Feeding

Load Preparation



The Loading Cycle


Loading the container

• The SKUs are fed to the row forming device where they are stacked horizontally

• The row of SKUs is moved to the delivery device where they are transferred and

placed inside the container

Scanning of rows


The Unloading Cycle • System scans the position, orientation/angle, and height of trailer then identifies the bottom of

the row that will be picked

• The row of packages is pulled on the delivery device

• The delivery device transfers the packages to the row forming device where they are

dispatched one by one

Unloading The Container

• Single packages conveyed &segregated to the palletizing stations

Palletizing



Features & Benefits Features • Increase of fill rate of container to 95%, (typical fill rate

for pallets feeding is about 75%)

• Speed is one container every 45-50 minutes, instead of 4 hours, by manual loading

• No truck modifications

• System is reversible and can be used for loading and for unloading, automatically

• ERP system can be incorporated to the system

• Different types of secondary packages can be used: cartons, shrink packs, polyouter bags

• Accurate control of truck load, and count of each SKU in the truck

• Labor savings and better ergonomics for the workforce

• System is movable and can be used on multiple trucks.

Benefits • Increasing trucking capacity by about 20%

• Reducing loading cycle time and increasing time of trucks on the road

• Possibility to use rented trucks or sub suppliers

• Reduced time during unloading of containers

• Inventory control and for optimizing loads of trucks

• Production control and monitoring

• Versatile for all production SKU’s and universal

• Inventory control

• Lower TCO

• Elimination of lost time while truck is maneuvering and packing



ROI



The Pilot System


The automatic truck loading with loose packages has been developed for a multinational

company with roll out potential.

Due to confidential reasons the video of the prototype can’t be shared, however it can

presented on request.

Below is a snapshot taken during the FAT in our plant.


IIOT Concept

Industrial Internet of Things

Central and Remote Management Level (IIoT):

• Consists of a network of intelligent devices.

• Collects and shares huge amounts of data and reports through a central Cloud-based service.

• Data and reports can be accessed and monitored remotely.

• Doesn’t require human interaction.

Control and Automation Level (Machinery):

Can be integrated on Technica equipment as well as on other suppliers equipment.


Plant View

Displays all the lines’ status:

• The green dot indicates an error free.

production line while the red dot.

• indicates a fault production line.

Displays the data calculated at a plant level:

• OEE

• Energy Consumption.

• Production reports.

• Alarms and messages.



Machine View

Ability to zoom in display data at machine level:

• Motors connectivity

• Overall events history

• Operator controls’ status

• OEE

• Energy consumption

• Motors’ Currents

• Motors’ Temperature

• Alarms & signals

• Events history

• Statistical reports

• KPIs

• Warnings & messages




Output reports

Alarm

s G

raphs N

otifications (em

ail/sms)


Impact of IIOT


IIOT

Improve troubleshooting & safety Lower costs

Better service levels

Increase process efficiencies Higher productivity

Streamlined maintenance

© Copyright 2014 Technica All rights reserved. No part of this presentation in all its property may be used or reproduced in any form or by any means without a written permission.

Documents

Content · 2019. 11. 6. · Content Presentation of Technica Family business Company profile End to end solutions Innovative solutions Light weight bottle storage solutions Multi-product