Discharge from the corrugator
The corrugator hall is the heart of the new plant. A unique feature is the use of three stackers in the corrugator discharge area. The flexibility in the discharge of the format sizes supports the order variety by the combination of these stackers.
Block multi-stacker behind the corrugator
To optimize space utilization in the high-bay warehouse, MINDA has integrated a block multi-stacker behind the corrugator to stack several stacks on each other. This makes it possible to multiply part runs from the corrugator up to a maximum stack height of 2,200 mm. This significantly reduces the number of required storage spaces in the high-bay warehouse, thereby increasing the efficiency of warehouse logistics.
Pallet loading station (BoP) behind the corrugator
In the corrugator hall, the stacks can be immediately positioned on pallets after the corrugated board has been produced. The pallet loading station (BoP) supplied by MINDA handles format sizes from 500 mm to 6500 mm.
Intralogistics connection to two high-bay warehouses
MINDA supplied the entire conveyor technology, including control systems for infeed and discharge for both high-bay warehouses. The plant layout includes a high-bay warehouse for raw and semifinished goods and another high-bay warehouse for finished goods. Storage in the high-bay warehouse is possible up to a width of 5,500 mm. The intralogistics process in the pre-zone is particularly decisive for high efficiency. The defined interfaces set maximum requirements to ensure consistent automation. The stacks are positioned by MINDA components with an accuracy of 10 mm. Up to four loading units can be prepared for discharge at the same time and assembled to a stack by a pusher. The storage and retrieval machine then takes these precisely aligned loading units directly to the storage location.
Converting machines connected on two levels
A special highlight of the new TRICOR plant is the connection of converting machines on a second level – beside six converting machines on the ground floor. Two vertical lifts continuously connect the ground and upper floor for this purpose. They transport finished and semi-finished goods between the levels, and provide bridging functions – for example, as a return line. The stacks are fed for conversion on the second level either via one of the vertical lifts or via the second high-bay warehouse. This is connected to the second level via two separate feeding lines. The storage and retrieval machines located in the corresponding aisle of the high-bay warehouse can both deliver to the discharge to the second level, leading to high demands for flexibility of the intralogistics located there.
Pallet securing line with two pallet loading stations (BoP)
In the pallet securing line, the stacks are palletized fully automatically using two pallet loading stations (BoP). The system automatically detects whether a stack has already been fed to the line with a pallet or whether the stack still needs to be positioned on a pallet. The loading stations are supplied via an integrated empty pallet storage with pallet inspection system. The empty pallets are fed fully automatically to both the loading stations in the conversion hall and the loading station in the corrugator hall.
Continuous digitalization and a wide range of interfaces
The intelligent control and visualization software MINDA MoveIT ensures that each stack can always be clearly identified. Continuous material flow tracking always provides customers with complete transparency. In addition, statistical evaluations are available, such as how many blocks are transported to which machine, what performance data is available and where potential wear and tear hotspots appear. These key figures provide TRICOR with valuable information on the use of individual converting machines, support predictive maintenance, and enable optimized production planning. With MINDA MoveIT, TRICOR relies on consistent visualization as well as on an intelligent control system that contributes to increased production efficiency thanks to comprehensive analysis.
Complete solution on two levels
For the equipment of its new plant, TRICOR decided on MINDA as complete provider of intralogistics from a single source. Together, they developed a layout with intelligent material flow that is particularly space-saving and considers the large formats that are to be transported through the production halls in different orientations. TRICOR benefits from a single contact for the entire planning and execution of the project. Integrating the second level with converting machines transforms the system into a threedimensional structure: rather than relying solely on horizontal material flow, this vertically networked production layout optimizes space utilization, reduces throughput times, and supports a high degree of order complexity. This architecture exemplifies smart intralogistics in the corrugated board industry.
