Faced with an increasing demand for production and safety in the end-of-line process, Thermal Insulation (specialised in the production of high-quality thermal insulation materials and part of the renowned Polyplast Group) identified the need to optimise the workflow, from material handling to packaging and storage of finished products.
The main challenge faced by the Pescara-based company was to ensure an efficient and well-organised warehouse while reducing cycle times and improving material protection at all stages of the process.
After a research and scouting phase, the choice fell on the technologies and technical know-how of Aetna Group. The latter - thanks to proactive listening and the ability to create tailor-made solutions, provided a comprehensive fleet of machines to meet the customer's requirements.
To meet the challenges faced by Thermal Insulation in the Collecorvino plant (province of Pescara), several business units of the Group were involved. These included: OCME, Robopac Systems and Sotemapack, which have worked together to make this project a success.
Specifically, two LGV laser-guided vehicles (the Auriga 8CT manufactured by OCME) were introduced for internal logistics. The Auriga 8CT counterbalanced vehicles with forks provide an innovative solution for internal material handling. Equipped with advanced space management algorithms, they enable optimal load distribution, maximising the use of available space and improving overall warehouse efficiency.
In this way, the primary goal to improve product management, line infeed, and picking of finished products was successfully met. Through careful management of product handling operations and precise control of the LGV forks, the ambitious goal of achieving zero damage during pickup was accomplished. An increase in safety is also evident in the advanced shuttle systems, which are designed to stop promptly when obstacles are encountered. Thanks to this implementation, significant improvements were made in terms of minimising errors and ensuring a smooth supply chain.
Another chosen solution - in this case from the Robopac Systems brand - is the Helix 3 EVO automatic rotary arm wrapping machine.
This machine is designed to precisely and securely wrap palletised loads using stretch film, ensuring an even, strong coverage for optimum sealing during transport and storage. The packaging process involves the manual loading of the products onto a floor conveyor to transfer the pallet for wrapping operations. This includes the application of a top cover sheet to protect the product on 5 sides. The wrapping machine's pre-stretch carriage features a dual-motor to ensure the correct film application on the pallet, which can be adjusted from the control panel.
Thermal Insulation chose the Stretchpack 130 S IL by Sotemapack as the best option for applying tensioned roofing film to loads. This machine has been configured to wrap products on all four sides, offering complete protection and a high-quality finish. With an operating speed of up to 10-12 packs per minute and a size to suit the company's needs, the Stretchpack 130 S IL has proven to be an efficient and reliable solution for improving the packaging process.
“Our production facility at Castilenti in the province of Teramo has also achieved optimal results,” adds Ambrogio Donatelli. “Unfortunately, we were previously using a (new) stretchhood machine purchased from another company just a year ago. However, this did not satisfy us in terms of speed but, above all, in terms of cost, as it required a lot of plastic material applied to the pallet.” “However, today we can count on an automatic and extremely reliable technology, working 24 hours a day in three shifts for five days a week, with a production of more than 500 pallets per day.”
Thanks to the implementation of the Aetna Group’s solutions, Thermal Insulation has seen significant improvements in its end-of-line operations.
The overall efficiency of the warehouse has been significantly improved, optimising time and increasing productivity.
In addition, optimal protection of thermal insulation materials was achieved at all stages of the process.
