Complex Material Handling System First in North America

 In the woodworking industry, the manufacturing process is rarely easy. One Creative Automation customer desired to enhance their processing throughput but found a bottleneck at, of all places, the end of the line where stacking the finished product occurred. Too much labor, too much handling, too much damage, and too many errors were hampering throughput. Yet a completely automated material handling system that could handle unique edges, contours, shapes, and sizes had never been successfully implemented in North America and perhaps the world.

Features of This Material Handling System

Some of the following features were incorporated for the first time in the countertop industry:

  1. System is a comprehensive stacking system at the end of a high-pressure laminate (HPL) countertop production line.
  2. The complexity stems from the backsplashes, builddowns, array of different edge styles offered, and the challenge encountered when nesting them automatically.
  3. The barcode on each countertop is read by Creative Automation equipment, which sends the countertop’s unique “serial number” to the customer’s server, which then replies with pertinent data for the countertop. This data enables the system to determine stacking logistics, including pallets to stack on and proper nesting.
  4. All functions are automatic. Human hands do not touch the product throughout the process.
  5. A large number of stacking locations are used at any given time because the customer produces like product for many of their customers at the same time. This scheme greatly reduces the number of changeovers on the main production line.
  6. A safety PLC and additional safety equipment ensure the stacking gantries operate safely in their respective areas and that personnel removing completed loads and reloading empty pallets are safe.

Equipment Functions in the System Include:

 Specific guidelines for performance and function were implemented here, providing the customer with exactly what they needed for their production environment.

  1. For countertops with a mitered cut, miter scrap is taped to the countertop to keep it with the countertop for stable stacking.
  2. End protection buttons are applied to countertop ends. Vibratory feeder bowls feed buttons to guns.
  3. A storage/retrieval carousel stores countertops to be retrieved later to be joined with another countertop, both stacked together on the same load.
  4. A turnover flips countertops as needed prior to the stackers so that they can be efficiently nested with other countertops already on the pallet. Nesting of countertops is complex because of backsplashes, builddowns, and an array of edge profiles.
  5. After the turnover, barcode labels are placed on the end of each countertop.
  6. Protective material is extruded on countertops so they do not rub on each other during shipping.
  7. Spacer sticks are applied as necessary so that each layer sits flat and is adequately supported on the load.
  8. Stacking is performed simultaneously by two high-speed servo-driven 4-axis gantries.
  9. A total of 38 stacking locations are divided up into three distinct areas. At any point in time, stacking can occur in one or two of these areas while completed loads are being removed and empty pallets are being inserted in the other area(s).

Bold Thinking. Can-Do Mindset.

Creative Automation has worked with this customer for many years on numerous projects, and the respective development teams have brought about several proprietary capabilities that are leading the industry. When bold initiatives are met with a can-do mindset on both sides, processing abilities that had not previously been attempted can be successfully implemented. These are the challenges on which Creative Automation thrives.

If your company is facing a serious processing challenge as you move your company forward, consider Creative automation when in the “dream” and planning stages. Our expertise and woodworking industry experience have yielded bold solutions to complex production problems for over five decades. Call us at 715-223-6321 and review our engineering, manufacturing, integration, and installation commitments before you call.