Producers gain a significant edge in time-efficiency and energy-efficiency with automation in cement packaging. High-speed, enclosed packaging of bulk goods improves hygiene, safety and throughput rate. But the empty bag transport still poses a bottleneck in cement production. Using automation to increase efficiency and safety provides and ensures more available work capacity and a stable, reliable and safe cycle is a relatively recent development in this part of the process. HAVER & BOECKER is leading the way with the robotic bag handling systems AMICUS® and PATHFINDER®.
The hidden bottleneck
A major, often overlooked challenge in cement packing lies in empty bag logistics rather than in the packing machines themselves. While filling and palletizing are increasingly automated, the flow of empty bags to the packers is still frequently handled manually, which slows the entire line. Why is this, and what makes it worthwhile to automate empty bag movement?
Why do producers still handle their bag logistics manually?
A more common challenge is tight space. The architecture of most plants simply doesn’t seem to allow for additional systems to store and navigate pallets and empty bags. Often, empty bags have to be stored in separate areas far from the packing station, which makes transport costly and time-consuming. As you might expect, production can be delayed when workers have to transport the pallets across operating machines, which produces hold-ups. On top of the lost time, manual pallet movements expose workers to repetitive lifting and frequent crossings through active machinery, increasing ergonomic and safety risks. In many plants, for instance, operators have to work in tight spaces within close proximity to the packing machine to deliver empty bags, which is not ideal.
How can the PATHFINDER bag transport help?
With the RADIMAT-PATHFINDER® bag transport, cement producers can store their bags in a central location further away from the packing machines and still achieve fast and reliable transportation across the plant. It’s a completely flexible bag logistics system that enables higher throughput rates despite spatial limitations. Ready for implementation into any setup, the compact bag transport system takes up little lateral clearance along the route and can be shaped flexibly in both its length and route to navigate around existing equipment.
The continuous, smooth transport especially benefits producers looking for high-capacity output. Compared to manual transport, where a worker may be able to handle up to 2000 bags per hour in ideal conditions, the automated system can handle up to 6,000 bags in the same time. It also brings a significant space advantage as the bags can be fed directly from the PATHFINDER® to the packing machine. Instead of operating a large RADIMAT® bag applicator next to the packing machine, manufacturers can save space by installing the narrow PATHFINDER®. Automated bag transportation systems will ultimately save costs by minimizing errors, reducing manual labor and ensuring constant bag supply. The possible increase in capacity and reduction of manual labor will further result in more productivity and profit gains. The adapted process also improves workers’ health and safety, as they don’t have to operate in close proximity to the machinery anymore. Relieved from risk-prone transport through the operating plant, workers can instead focus on quality control and troubleshooting to keep up a smooth process without disturbances.
HAVER & BOECKER has already equipped plants with the PATHFINDER®, connecting storage areas with packaging stations across distances of up to 20 meters. The RADIMAT® empty bag applicator can handle different bag types and feed them to the PATHFINDER®, allowing for more flexibility with suppliers and easy integration into different packing machines. This setup is especially profitable for manufacturers with limited space, as placing the RADIMAT® at a distance—protected from dust—reduces the "lost angle" between the applicator and the full bag conveyor by 10%. Together, these machines form a continuous, automated route from central storage to the packing machine, replacing manual pallet and bundle movements. This setup can become even more efficient with the addition of further robotic technology.
How do robotics empower automated bag handling?
In order to harvest the full potential of process automation, the PATHFINDER® can be combined with the camera-guided AMICUS® depalletizing robot. This robot places empty valve bag bundles reliably from the pallet onto the RADIMAT®, which separates each individual bag and feeds them onto the PATHFINDER®. The AMICUS® robot works with intelligent camera recognition, trained to handle multiple patterns and suppliers. It also securely grips unstrapped bag bundles, which makes additional plastic straps obsolete. This not only reduces consumable material but also simplifies logistics and supports more sustainable packaging practices. The equipment offers a low-maintenance solution compared to mechanical palletizing equipment, significantly lowering operational costs in the long run.
With automated solutions like the PATHFINDER® and AMICUS®, producers can ensure consistent bag supply for their packing machines and keep output rates at a high level. Camera-guided logistics further streamline the whole production process, from central bag storage to palletizing, and allow for more flexibility concerning bag types and supplier changes.
The system’s adaptability is a central advantage for producers as it can be adjusted to any plant setup and integrated into the operation smoothly. HAVER & BOECKER offers tailored consulting for these flexible bag logistics to fit your existing setup perfectly.