PPMA-Group-News-Autumn-2018

Hair-raising challenge
for shampoo line
A demanding brief proved no barrier to the delivery of
an end-of-line packaging solution for Unilever in Dubai
When Unilever decided to build two high
speed packaging lines (350 products per
minute) for its shampoo and conditioner
products at its new state of the art
personal care factory in Dubai, it was a
challenging brief, not least because of the
complex shapes and unstable design of
the bottles. The solution would need to
be able to handle eight different container
formats with a large scope of sizes (from
100 to 900ml), yet meet a maximum
10-minute line changeover multiple times
per day.
The company turned to Gebo Cermex,
who took a robotic approach at the
product collation stage. The designers
removed many mechanical parts typically
used, ensuring easy access to the heart
of the machine. They opted for a product
management solution through six robots,
using FlowDesigner® (Gebo Cermex’s
flow management and product tracking
intelligence) for gentle bottle handling
and continuous batch preparation. This
enabled precise product positioning on
the shrink-wrapper infeed conveyor, as
well as fast changeovers. Changeovers
were further simplified by integrating a
single universal gripping head for all eight
bottle formats.
Embracing change
A thermosealing shrink-wrapping solution
was implemented to ensure that the
pack was of a high quality; that a limited
number of product transfers would need
to be adapted for shaped or unstable
bottles; and that it would be possible
to switch from one to three product
lanes. For case erecting and packing,
as well as case sealing and palletising,
changeover needs were met with either
universal systems or fully automatic/
auto-adjustment processes. The packer
is a secured pick and place solution with
a gantry case packer that allows for fast
and simple changeovers.
“We can meet the very demanding
requirements of the food, home and
The Unilever Dubai
factory produces
500 million hair and
skincare products
under the Dove, Fair
& Lovely, Lifebuoy,
Vaseline, Clear,
TRESemme and
Sunsilk brands
At a glance
Challenge: How to implement
two high speed packaging
lines handling complex and
unstable bottle designs
Solution: A robotic approach
ensures gentle handling of
eight different container
formats
Outcome: High quality
packing, continuous batch
preparation and fast
changeovers are now the norm
personal care sectors; such as care
handling of sophisticated containers,
ultra-flexibility, and the high demand
for line speed increases,” states
Jean-Philippe Beduneau, Strategic Key
Account Director for Unilever at Gebo
Cermex. “Our existing portfolio is also
able to respect the specifications typically
linked to shaped, unstable bottles.
Nevertheless, in the case of Unilever, their
expectations of line speed and maximum
time for changeovers challenged our
design department to stretch the
boundaries of the current range and
merge modules and technologies like
never before.”
www.gebocermex.com
Unilever now has
two high speed lines
capable of handling
eight different
container formats
Luxe-loving solutions
Short production runs often associated
with exclusive or limited edition luxuries
are another reason for manufacturers
to consider adopting offline coding.
Rather than installing a printer on each
production line, a single offline system
can cater to different packaging types
and product ranges. Furthermore, thanks
to solvent-based technology, today’s TIJ
printers can also apply code directly onto
glossy surfaces prevalent in the luxury
brand market, often with greater clarity
than continuous inkjet (CIJ). And because
TIJ systems print at a resolution of up
to 600dpi, the font of any overprinted
information can be adapted to match
the carefully designed branding on the
package. Likewise, if brand owners prefer
coded information to be clear but not
too eye-catching, TIJ print density can
be lightened. In addition, the cost per
character using TIJ can be four times less
expensive than CIJ.
During the next few years, the luxury
packaging market in Western Europe
is predicted to grow twice as fast as
packaging overall. Therefore, premium
brand owners need to consider how
they will continue to catch the eye of
luxe-loving consumers, without damaging
brand reputation with poorly placed
codes.
As Rotech’s Richard Pether says:
“Premium packaging is the single
touchpoint for consumers and the quality
should speak for itself. This applies as
much to the packaging container itself as
the codes on it.”
www.rotechmachines.com
7 www.ppma.co.uk