Nowadays, in the big picture of global economy, if China’s manufacturing industry wants to possess stronger competitiveness, the progress of developing technologies of logistic equipment is essential. Statistics shows that in China, the cost of logistics occupies 18% in the whole manufacturing costs. So logistic management and the cost control is now a fatal key of influencing products’ competitiveness in the market, and inseparable with the benefit of an enterprise. Meanwhile, the new economy, represented by E-business and crowdfunding, is permeating in our daily life. The new economy has changed fundamentally its patterns of satisfying customers’ needs, in which, it focuses more attention on quick responses, and individualization. This requires enterprises re-organizing the production process, and demands higher for efficiency, flexibility and traceability. And to link the production line’s logistics is a very important support for intelligent manufacturing.
In recent years, the application of automation is getting vaster and vaster. Production capacity is boosting, whilst the conflict between with storage capacity is getting more obvious everyday. Meanwhile, the land and labor costs are increasing, which makes the monotonous and traditional discretized storage mode，in which available logistic equipment or staff are used to operate the transition and transportation of products, raw and auxiliary materials, lag behind the pace of development in this era.
To carry out in a deep way of the actions to cut the costs, optimize the quality and speed up the efficiency of work, complete the mission of building customers’ ideal factories, and smoothly realize the green sustainable development of enterprise, Newamstar has been chasing for the marching paces of Industrial 4.0 Era, taking the leading role in integration, promotion and application of modern logistic technologies in automatic stereoscopic warehouse, building the “intelligentized factory system”, providing new concepts and methods in the reform and establishment of the intelligentization, automation, modernization of future beverage industry, with the foundational fact of accumulated rich experience in relevant industry and the fact of having provided more than 1500 production lines for famous merchants all over the world.
Evolution evokes development, innovation creates legendary, and originality molds characteristics. Throughout more than one year’s business survey, products’ technological development, and integration of the resources, Newamstar is now able to make an impeccable logistic management system, combining automatic packaging production line with automatic stereoscopic storage system, for the future customers, by outstanding RD team and the advantages in manufacturing equipment.
According the pro-phrase program, our customer had purchased the 24000BPH whole packaging line, the volumes of which are 350ml and 1500ml. Carton is used for packaging, whose lowest in house capacity is 10 plates per hour, the out house is 90 plates per hour, and the effective storage capacity is no less than 2500 plates. The packaging line locates on the 2nd floor of the workshop, and the finished cartons will be transported by spiral conveying machine, and palletized on the 1st floor.
The height of 2nd floor is 14m. Net height of stereoscopic warehouse installation is 12.65m. Floor area is 1600 ㎡. The stereoscopic warehouse is linked with palletizer with conveying units, to achieve the design of delivering out empty plates and input full plates automatically.
The whole program is centering on the automatic stereoscopic warehouse project. On the primary stage of the project design, our company offers the two-in-one resolution plan, by referring to the needs of customer in storage capacity, and utilizing the characteristics of the high utility rate of shuttling garage space and the automatic access of the lateral palletizer. The palletizers sit on the two ends of shuttling garage, to simplify the shifts of shuttle trolleys and the access of the warehouse.
Pros: high utility rate of space; large storage capacity.
Cons: under the limitation of the site and palletizers, the large flow of single type product ex-warehouse is hard to be reached.
Adjustment of project
By repeated communication and verification with customers, the layout of automatic stereoscopic warehouse with double stretchable roadway was finally chosen, which balances the storage capacity and ex-warehouse ability, by using efficient utility rate of space of this kind of design and the collective performance of the multi-lateral-palletizers.
Introduction of the System
The automatic stereoscopic storage system can automatically distribute the palletized products according to types, batches, etc., and convey to correspondent ends of good claiming of the warehouse, under the control of WMS storage computer management software. Meanwhile, the operation units for claiming goods will be controlled by computers. Under the rules of in-and-ex warehouse, the allocation and storing will be autonomous. When execute the ex-warehouse mission, the operation units receive the commands from the WMS, and carry out the mission der the principal of prioritizing the early in-warehouse goods, and transfer the goods to loading section automatically.
The system integrates bar code scanning and management parts and is connected with company’s ERP system, which is good for the comprehensive control and monitoring of material information.
The automatic storage system mainly covers the following units:
- The transit and storage of the goods – high shelves and plates
- In-and-ex warehouse equipment – pelletizers and shuttle trolleys
- In-and-ex warehouse allocation system – conveying machines, RGV conveying trolley.
- WCS control system – all the in-and-ex warehouse equipment, allocation system, electronic devices for inspection and security are controlled by computer.
- WCS warehouse management system – showing the conditions of resource administration, locating management, data analysis, operation of the equipment and storage situation, connected with ERP, and sharing the control of all materials and information.
RF bar code scanning and management system – collecting information of goods, and connected with WMS system to arrange and gather material information.
In-warehouse Operation Procedure
The packed products are transferred to palletizers by the conveying units. Palletizers send out the empty plates commands, then the pilers take out the empty plates from the stereoscopic warehouse, and transit to the transportation unit entrance of empty plates by RGV trolleys.
The empty plates are disassembled by the dismantlers, and palletized in the palletizing area. The full plates will be sent to the transport RGV vans by wheeled and chained conveying systems, during which, the scanning devices will scan the bar codes of the plates. The information of plates and products will be interacted in ERP and WMS systems.
RCV trolleys communicate with WMS system through Wi-Fi, and are assigned with the addresses of different in-house lateral palletizers under the control of WMS system, transported steadily to the correspondent in-house units, under whose control, the storing work will be undergone with the system-appointed addresses.
Ex-house Operation Procedure
The ex-house operation plan is generated by the ERP system, and sent to WMS system by Internet. After the WMS system receives the plan, internally processed, it will optimize the ex-house efficiency and give out the ex-house command. The lateral palletizers will follow the instruction and execute, under the situation in which the in-house work is completed. Palletizers reach the required location, find relevant goods automatically and transfer them to the ex-house units.
WMS system simultaneously shows the demands of goods on the LED screen, on which the patch code and specifications of the goods, license plate numbers can be seen, along with the notice of the location of unloading to the drivers.
Advantages of the Project
The system improves the utility rate of space and the performance of in-and-out warehouse in a limited space, which realizing the balance of storage capacity and work efficiency. Due to the application of the direct connection with packaging production line on the layout, the middle transition and transportation vehicles are less needed. Through the modern Internet technologies, the sharing and connection of data between ERP enterprise resource management systems, MES executing systems and WMS warehouse management systems are realized, by which, less faults are made and the whole process are speeding up. Comparing with the traditional discrete warehouse, the new ones save a huge investment of land, reduce the labor intensity, better the working environment, cutting the labor costs, and eventually make the integration, automation, intelligentization of the packaging and storage systems come true, and optimize the production effect and modernized management level.
NEWAMSTAR HIGH-SPEED BLOWING-FILLING-CAPPING COMBIBLOCK
Newamstar High-speed Blowing-filling-capping Combiblock combines the blowing system, filling system and capping system in one integrated system, reducing several intermediaries suchas transmission, empty bottle handling and storage processes, which improves packaging hygienic condition and reduces packaging ross-contamination so as to improve the overall operating efficiencybut lower the energy consumption, thereby reduces the overall production cost of enterprises.
- Product Range: Production capacity from 12,000 BPH to 80,000 BPH.
- Applications: It is applied to PET bottled pure water, carbonated soft drink, juice, liquid dairy, liquid condiment and household & personal care products, etc.
Stable infrared ray heating system and independent heat balance device ensure the stable temperature of the preform, even color of the bottle and increase of the output.
Special designed twice-blowing system can monitor the pressure in each mold in order to provide accurate real-time parameter for operator. It is easy for the operator to adjust the parameter and ensure the stability of bottle forming.
High-speed and high-accuracy diaphragm type filling valve: Equip air back channel which is separated from liquid carousel, by which, the air replaced from the PET bottle won’t enter liquid carousel to avoid second pollution. Equip cleaning dummy bottles which can realize online CIP.
Sanitary and washable capper：Optimized cam surface design ensures the minimum
impact force of the capper .Bottle discharging starwheel is screwing decently, so it is unnecessary to adjust the conveyor height during bottle format change.
Driven by innovation and win the market by quality!
Newamstar has focused on liquid packaging industry since from its establishment. Taking innovation as guide and basis, we have been forging ahead constantly.
As an outstanding company in China high-end equipment industry, Newamstar has built a dimensional product system gradually including beverage, milk, alcohol, condiment and daily used chemicals. We have won many innovative “China First” for various products. All these achievements and milestones will be fixed and memorized in the long history of Newamstar.
INTELLIGENT STEREOSCOPIC WAREHOUSE SYSTEM: THE FIRST CHOICE OF BEVERAGE FACTORY TO UPGRADE THE MODERN WAREHOUSING AND LOGISTICS!
In recent years, with the increasing of automation and production capacity of liquid food packing line, contradictions between inventory and production capacity have become increasingly prominent. At the same time, with the increase of land cost and labor cost,traditional discrete model of warehousing and logistics using single logistics equipment or personnel to carry out the transportation of product and raw materials has been outdated.
With the deepening of “industry 4.0” and “Internet +” concept, the Chinese industry is transforming from the traditional labor-intensive to the industrial automation, and the traditional management mode based on people is turning to computer-based Information and modern management. Intelligent equipment represented by robot and a new generation oflogistics model with the function of data collection, management and data tracing is being more widely used in the market.
As the Chinese leader in the field of liquid packaging, Newamstar accumulated rich experience in long-term development. By industry research, product technology development and the integration of industry resources over one year, Newamstar introduced the concept of “Internet +” into the production line followed by the pace of “Industry 4.0”. On the basis of rising the capacity and stability of liquid packaging production line, Newamstaroptimized the structure of production lines and improved the level of automation of the production line by reducing the cost, and improving the quality and efficiency.
- Goods transition and storage – high rise shelf, tray and container.
- Check in & out device – palletizer.
- Check in & out distribution system – roller and chain conveyor, distributing vehicle, lifter, etc.
- WCS control system – includes check in-out device controlled by computer, distribution system, various kinds of inspection and safety device controlled by electricity.
- WMS warehouse management system – warehouse account management, data analyzing, goods site arrangement, device operation and warehouse storage display, etc.
A double extension tunnel stacking machine is adopted in the projects of“Moon over a Fountain Co. Ltd”, which achieve an effective balance between capacity and efficiency by improving space utilization and flexibility of warehousing in a limited space. The production line is connected with the warehouse directly, so a lot of material transfer links was saved. With advance internet technology, it realizes the resources and data sharing and connection between the ERP(enterprise resource management system), MES (manufacturing execution system) and WMS (warehouse management system) to reduce the mistakes and speed up access of the goods. Compared with the traditional discrete warehouse, Intelligent stereoscopic warehouse system can save the cost of land investment, reduce labor intensity, improve the working environment and reduce labor costs, finally improve the production efficiency and the level of modern management by making packaging and storage systemIntegrated, automated and intelligent.
In 2015, with excellent R&D design team and processing advantages of equipment manufacturing, Newamstar completed the development of automated warehouse system with tunnel stackerand RGV rail transport trolley. In the same year, Newamstar successfully presented it on CBST exhibition in Shanghai, and received wide attention from lots of companies in the industry. In 2016, automated material transport under special circumstances is solved by researching and developing non-rail AGV transport trolley. Through the introduction of advanced visual logistics simulation software FlexSimand excellent simulation designers, we can make simulation test in the project planning process, and do all kinds of system analysis and engineering verification for the model to get the final optimized the design. It can also quickly confirm the logistic equipment solution, further verify the feasibility of the project, provide improving and management basic data for the system, and reduce operating costs of production enterprises.
Currently, Newamstar are upgrading internal logistic systembased on stereoscopic warehouse system, will build automated logistics system by using AGV non-rail Intelligent trolley to distribute the raw materials, and create a new automated management system with the product lifecycle management, process management and information management.
New age, a new chapter, a new dream. With the evolution and promotion of intelligent stereoscopic warehouse system, it will help beverage manufacturers to clarify and refine requirements, quantify data target and accuracy control of the production process, and finally help to realize the intelligent, automation and modernization of plant.