Solutions for the Thermoforming Industry: Labour Saving & Operator Ergonomics

In today’s thermoforming industry, businesses face significant challenges such as frequent machine changeovers and operator ergonomics and safety concerns. At Delta Engineering, we recognize these hurdles. Our end-of-line automation solutions bring about labour cost savings by increasing operator efficiency and eliminating dead time, while also improving operator ergonomics and safety.

Our Solutions:

1. Thermoforming Product Lift – DBL302:

   • Functionality:

     This product lift with a buffer belt is typically positioned behind the thermoforming machine. It lowers products to operator level while simultaneously buffering them.

   • Benefits:

     By allowing operators adequate time to switch between thermoforming machines for packing, the DBL302 can drastically reduce labour costs and enhance workflow efficiency. It also eliminates the need for platforms and its safety risks.

2. Vertical Buffer System – DVB122:

   • Functionality:

     This vertical buffer system can be positioned behind the DBL302 or directly behind the thermoforming machine, to enable additional buffering on a compact floorspace (only 2100 x 1500 mm). The DVB122 can buffer up to 8 layers of 1200 x 1000 mm, moving the products upwards. The products are automatically debuffered when the operator clears the exit conveyor.

   • Benefits:

     The DVB122 allows operators to handle multiple thermoforming machines instead of just one, which results in additional labour cost reductions.

      

3. In-Line Metal Detector – DMD302:

   • Functionality:

     This in-line metal detector ensures consistent product quality by identifying metal contaminants during the production process. The DMD302 can be integrated seamlessly into your existing production setup.

   • Benefits:

     By ensuring the compliance of your production line, the DMD302 protects both your product integrity and consumer health – essential for food safety.

      

4. Ergonomic workstation – DBC302:

   • Functionality:
     The DBC302 is a workstation designed to improve operator ergonomics and efficiency during the packing process of thermoformed products as they exit the thermoforming machine. This workstation features a height-adjustable buffer conveyor with a control system, two height-adjustable box holders, a holder for a label printer, a holder for an HMI screen, and a lamp tower. It can be placed behind a DBL302 product lift.

      

   • Benefits:

     • Operator Ergonomics:
       Operators can quickly adjust the height of the conveyor to match their individual height, which significantly improves ergonomics. Additionally, the workstation is customizable, allowing operators to modify box positions according to their preferences, and to easily incorporate a label printer or an HMI screen using the workstation’s holders.

     • Labour Savings:
       As the DBC302 buffers the products, operators can pack products from multiple thermoforming machines, leading to significant labour cost reductions.

5. High-Speed Thermoforming Sheet Spray Coater (DSC304):

   • Functionality:

     This high-speed spray coater is designed to give anti-static, anti-blocking and anti-fog properties and to improve slip properties (demoulding) of thermoforming films. Our spray coater can be placed before the thermoformer or after the extruder, and can utilize a variety of spray coating solutions.

   • Benefits:

     The food-approved coating is resistant to high temperatures, ensuring no damage during subsequent thermoforming, and maintains film integrity even under stretching. On top of that, it is silicone-free – perfect for subsequent printing!

Proven Results:

Our innovative solutions have demonstrated substantial benefits. For example, a thermoforming line equipped with a DBL302, DVB122 and DMD302 reduced operator load from two to one, achieving a short payback of 1-2 years.

Thermoforming solutions

Key Industry Challenges:

• Frequent Changeovers:

  With thermoforming machines often requiring multiple changeovers in a single day, automation is tempting. However, care should be taken that the operator is not exchanged for an engineer, who would be needed to do the complicated (and more expensive) changeover.

• Elevated Machine Output:

  Thermoforming machines typically have outputs at heights between 1500 and 1800 mm. This is why platforms are often placed around the output where the operators are installed, to allow them to pack what comes out of the machine into boxes.

  • Due to these platforms, however, the operators cannot easily switch between different thermoforming machines. This forces them to follow the speed of a single machine, which decreases efficiency.

  • The platforms also impose safety risks, as the operator can fall off the platform.

• Limited Space:

  Not only due to the output height of the thermoforming machines, but also due to the limited space available for buffering / automation, operators are required to remain in close proximity to the equipment. There is insufficient time to move back and forth between thermoforming machines.

• Product Stability Issues:

  Unstable stacks of thermoformed products exiting machines pose challenges, particularly with static energy attracting dust and causing stacks to topple.