NuLine Automation Advances Efficiency in Film Converting

The Challenge

One of NuLine’s customers in the film converting industry faced a daunting task: stacking up to 500 large, foil-lined gusseted bags per machine cycle. Each bag, ranging in size from 3x5 to 3x8 feet, presented unique challenges due to static cling or trapped air, making manual handling cumbersome. Operators, often positioned on low stools, performed repetitive motions that took a toll on their health and slowed production.

The customer needed a solution that could meet or improve the cycle times of their current machinery while ensuring uniformity, safety, and ergonomic improvement. Additionally, the system had to integrate seamlessly with an older machine already powered by OMRON technology.

The Solution

Drawing inspiration from processes used in printed paper stacking, NuLine designed a Cartesian robotic system tailored to handle the unique demands of bag stacking. The system integrates robust OMRON Automation technologies, including the NX102 Machine Automation Controller for precise motion control. The G-Series Servo Motors and 1SA Drives provide the speed and power required for efficient operation. To improve operator safety and prevent contact with moving parts, the system features FS3G Light Curtains. Additionally, the NA-Series HMI allows straightforward recipe management and manual control of the robotic arms.

OMRON’s engineering support played a pivotal role, assisting with motor sizing and selecting the optimal PLC and servo configuration. The automation control platform, Sysmac Studio, features an intuitive programming environment for simplified setup, ensuring the Cartesian robot met both technical and operational goals.

The Results

The system delivers precise and consistent stacking at high speeds, traversing a 4-meter span in under five seconds. It produces uniform stacks of 500 bags, improving transportation safety and efficiency. By reducing operator strain, the solution effectively addresses ergonomic challenges while shortening cycle times, leading to more productive shifts.

OMRON’s compatibility with top third-party communication protocols allowed seamless integration with other machinery, reducing downtime and ensuring a smooth transition. NuLine’s controls team provided exceptional technical support to the end-user, emphasizing the value of user-friendly programming tools as a key factor in implementing this advanced solution.