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Nachdem die Gesamtlösung prototypisch
evaluiert wurde, erfolgte die
Weiterentwicklung des Systems über
den Industriepartner INDYON GmbH
(München). Im Sommer 2005 wurde
das Projekt erfolgreich abgeschlossen
und inzwischen bewähren sich
die OPAK-Entwicklungen in der Praxis.
Damit zählt dieses Forschungsprojekt
zu den Beispielen für einen gelungenen
Transfer zwischen Wissenschaft
und Wirtschaft.
Carl Hans
Optimierte Verpackungslogistik
in der Kreislaufwirtschaft
The Challenge: A number of specific
aspects need to be taken into account
when carrying out process optimisations
in the recycling sector. In this context, the
key issues are the costs for the redistribution
of recycling material, the speed of the
backflow as well as variable quantities.
Supporting continuous process optimisation
in the areas mentioned above can
foster sustainable initiatives of companies
by offering an economic recycling of
materials.
The Project Optimized Packing Logistics
in the Life Cycle Economy (OPAK) was
conducted as a close cooperation between
the BIBA divisions IKAP and MAQ as
well as four industrial partners. The main
objective was the development of technical
improvements it is necessary for the
optimisation of process chains within the
recycling arena. The project focussed on
packing logistics for the flow of material
between the individual processing steps.
The recycling of plastics waste material
in production was selected as an
exemplary application field. Due to the
purity of this recycling material, a number
of business models already exist in this
area. However, optimisation would require
significant investments which would additionally
implicate considerable economic
risks for the companies involved (mostly
SMEs).
The Realisation: The solution implemented
in the project is based on RFID
technology. This was realised on two
different levels:
First of all, the process units (in which
the recycling material is contained
throughout the different process steps)
were equipped with RFID transponders.
The transponders allow the association
of these units with their content in terms
of process relevant information, such as
material type, weight or date of delivery.
Figure process unit: In addition to the
process unit related information, an RFIDbased
solution for positioning was developed.
RFID transponders were embedded
into the warehouse floor and sealed using
epoxy resin.
Figure RFID-Tag in the ground: RFID
readers mounted beneath the transportation
vehicles, e.g. forklifts, allow
the continuous tracking of their position.
Furthermore, ultrasound sensors and RFID
readers equipped on the fork enables the
automatic reading of the transponders at
the process units. Additionally, information
regarding the level of the storage rack
can be delivered.
Figure forklift: All of the additional
components on the vehicle are integrated
using an on-board computer which
communicates with a server via W-LAN.
Besides other warehouse information,
the server manages a model representation
of the grid of transponders embedded
in the ground. For tracking the position
of a process unit, the transponders
in the floor under the vehicle are read.
Subsequently, the ID of the transponder
which is delivered by the reader mounted
under the vehicle, is transmitted to the
central server. The vehicle’s current position
is returned by retrieving the position
associated with the ground transponder
in a database on the server.
The main advantage of the OPAK
solution is it‘s abitility to the integratied
existing business processes: Only those
areas which are relevant for positioning
have to be equipped with transponders.
Furthermore, the existing vehicle pool can
easily be upgraded with the additional
technical components required by OPAK.
The OPAK solution has been commercialised
by the industrial partner
INDYON GmbH (Munich). The project was
successfully completed in September
2005. In the meantime, the device has
been installed in various industrial sectors.
Thus the OPAK can be seen as a good
example of a successful cooperation
between research and industry. OPAK is
funded by the German Federal Ministry of
Education and Research (BMBF).
Carl Hans
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