SPECIALIST IN CHEESE TREATMENT WITH PASSION FOR CHEESE
SPECIALIST IN CHEESE TREATMENT WITH PASSION FOR CHEESE
SPECIALIST IN CHEESE TREATMENT WITH PASSION FOR CHEESE SPECIALIST IN CHEESE TREATMENT WITH PASSION FOR CHEESE
After collaborating for years on end, ELTEN and DERO now belong to the same company since the spring of 2012. Both companies have many years’ experience in the cheese branch when it comes to treating, handling, packing and/or transporting cheeses - in whole or sliced. Apart from our broad experience in treating cheese, we can also rely on over 25 years’ experience with robots, of which over 20 yearswiththeimplementationofrobotsinthecheese-processing industry.
Thanks to our knowledge, acquired experience and our stabile organisation, we were able to implement quite some cheese projects with enormous strength. We would be glad to also implement our expertise for your company. By collaborating, ELTEN and DERO are bundling their knowledge and expertise, and we can operate innovatively and decisively - both nationally and internationally. At the implementation of your project, you are dealing with one single company. Depending on the main point of the project, or you specific wishes, your project is implemented by ELTEN or DERO. The other party will collaborate as a partner.
This division is established in sound consultation, with the following result: short, clear and transparent communication lines during the implementation.
Above all applies: your situation is our starting point! PREFACE CONTENT 02 Content 03 Preface 04 Cheese treatment 08 Plasticising 09 Board washing 10 Control 11 Brining 12 Paraffin coating 13 Banding/labelling 14 References 16 Box-to-box 17 Loading and unloading boxes 18 Large packing 19 Small packing 20 Loading and unloading crates 21 Foil packing 22 (de)Palletising 03 PASSION FOR CHEESE! ‘It is our mission to offer our clients the most creative, innovative, and reliable solutions in the field of cheese processing.’ - DERO bv / ELTEN bv -
CHEESE TREATMENT ELTEN and DERO supply a wide range of solutions with a total concept for all (semi-)hard cheeses.
For each warehouse size we have a solution. We supply treatment lines with a capacity varying between 300 and 3,000 cheeses per hour, for instance. Acheesetreatmentlineconsistsofvariouscomponents.Defixedelementsconstituteof aplasticiser, aboardwasherandoneorseveralrobotsand/ormanipulators.Thesecomponentscanbeadd edwith the charge and discharge system for boxes, cheese and board transport tracks, and possible turners. A supply and conveyance system for boxes can vary from a system whereby the boxes are placed stationary on the floor, to a complete transfer system whereby the boxes are automatically supplied and conveyed, are transferred and - if necessary - rotated.
In the case of automatic box transportation we often work with shuttle cars. This sees to a flexible and maintenance-free system. Furthermore you can choose for a turner in the treatment line or for turning the cheeses during the robot flight.
Depending on the needs, we supply a small or larger cheese treatment line. Apart from the treatment of the cheeses and the shelves, various functionalities can be added to the line. The options range from cheese input, weighing, labelling, banding, re-boxing, and palletising to the delivery of the cheese. The main starting points at the development of our cheese treatment installations are that they have to be designed as compact and simple as possible; compact in order to save (warehouse) surface, and simple because of ease of operation, cleaning, reliability, and maintenance costs. In this way, a client-specific solution is created with the desired capacity and functionality based on proven technologies and tailor-made to the available space.
Solutions that we can offer for the various warehouse sizes and desired functionalities include: Mini-line This is the simplest setup. It consists of a plasticiser, a shelve washer, and a robot. The boxes are in principle placed stationary on the floor, but a box transport system can be added to the setup as well. The robot carries out all handling movements of the cheese and the shelves, including the turning, because of which a minimum of transport belts is needed. Depending on the design, this line has a capacity of 100 to 150 shelves per hour. Medium line This is a treatment line that was developed for short runs with various cheeses.
This line has a capacity of around 200 to 300 shelves per hour. The line is constructed flexibly and contains a plasticiser, a shelve washer, and a robot. The turning of the cheese and the shelves takes place by means of turners. The cheeses are carefully placed back on the cleaned shelves after plasticising.
The line is fitted with a separate cheese turn-around and therewith combines a higher capacity with a compact 05 04
shelves and the cheeses with a star turner, also sticky cheeses receive sufficient time to come loose of the shelf in a cheese-friendly manner. This prevents damaging of the cheese rind, which is especially important for young cheeses and cheeses with soft dairy contents. The shelves are soaked in a warm detergent before they are cleaned. Because of this a maximum cleaning result can be guaranteed. The handling of the shelves in and out of the box takes place by means of manipulators.
Apart from these standard lines, we also offer specific solutions for deviating cheese types or cheese treatment wishes. For instance, we also have solutions for several rows of cheese on one shelf, for very small cheeses, and for bread cheeses, Edam cheeses, and Mimolettes. The operation of all lines takes place based on line controlling with an integrated operator interface. All components of the line are integrated, because of which an extremely efficient control system is created. All hardware and software is developed, manufactured and tested by us. 07 06 construction. If desired, the line can be expanded with a labelling machine, a banding machine, and/or a weighing system, either in combination with a metal detector or not.
Compact line The compact line is a line that is based on robot technology. It is characterised by its simplicity, reliability, and flexibility. The line is suited for all possible boxes, cheeses and sizes, and is available in many varieties. The line is fitted with two robots: one for taking out and one for placing back the shelves with cheese. As a result of this, the line has an elongated construction. Turning the cheese and shelf is also handled by the robot. The shelf-run is located under the cheese-run. Because of this, a minimum of transport belts is needed and a compact line emerges.
Depending on the size of the shelf and the type of cheese, the compact line can achieve a capacity of 450 tot 600 shelves per hour.
Maxi line The maxi line is the line with the highest capacity. 650 to 700 shelves per hour can be handled. The capacity is independent from the shelf size and the box size. The line is fitted with a separate star turner and an extensive soaking section for the shelves. By turning the
PLASTICISING BOARD WASHING The way of curing is of great importance for the final taste of your cheese. The cheese rind plays an important role at that. This is made up by a cheese coating, also called cheese plastic or coating. We offer a reliable solution for the application of this cheese coating.
In order to apply the cheese plastic optimally, the Plastomatic, type Economic II, is used. This highly on- developed machine plasticises the top and 60% of the side of the cheeses. After plasticising, the cheeses are returned to the boards in order to dry and cure (further).
The settings for the various cheese types and sizes are pre-programmed. As a result, they can be easily selected via the operating panel. In case of a machine integrated in a complete line, this is done via the central line control system. Of course the programme also has a cleaning cycle. During that cycle, the brushes are rinsed and spin- dried, the brush hoods are rinsed, and the conveyor belt is cleaned. The Plastomatic combines efficiency with low maintenance costs. Among other things, this is because of the excellent plasticising results at low plastic consumption, the long standing time of the flaps, the quick and easy changing of the flap rollers, the easy operation, the limited pollution, and the minimal water consumption.
Rectangular cheeses can be plasticised optimally as well. For the thorough cleaning of the cheese boards with the highest obtainable hygiene, we have a unique and advanced system available whereby the board follow a complete washing programme. The system functions efficiently, requires little maintenance and can be kept clean easily.
Our shelf washing system cleans the shelves at the bottom and a part of the side. The top of the shelf remains dry. In order to be able to clean properly, time, temperature, mechanical (brushing) power, and a detergent are needed. Optimal cleaning is obtaining by applying a soaking section. Thereby the shelves are soaked with a detergent before they are washed. After the washing, the shelf is rinsed once again and dried. In order to maintain the temperature of the washing water, this system is equipped with its own heating unit. Also because of this, the system can be simply implemented in modules in a treatment line, or installed as a stand-alone unit.
Another meanwhile proven system that is applied as stand-alone is the robot shelf washer. Shelves can be washed on one or both sides with this washer. Outside the cheese treatment line, a robot sees to it that the shelves are placed from the box to the washer and vice versa. The shelves are either turned or not. The system can be composed with or without soaking section, depending on your wishes. 09 08
BRINING Our scope of delivery starts with conveying the cheeses from the brine bath. We ca narrange the conveying by means of transport belts in order to subsequently store the cheeses in the warehouse, possibly after a first treatment.
For the transport of cheese from the brine bath, we use bar or chain conveyor belts. Our scope of delivery starts there where the cheese leaves the brine bath. After the discharge, the cheese can be cured. We have developed a blow-off unit for that, with which the cheese is blown almost completely on each side during the transport. Often, the cheese is then directly conveyed to a treatment line in order to undergo the first plasticising treatment and to be entered into the warehouse system.
In order not to load the capacity of the cheese treatment line any further, or in order to generate extra capacity, we can supply a separate system whereby the cheese is plasticised and directly placed in the box. This installation - which is mostly placed immediately after the brine bath - requires a small floor surface, because of which the logistical course is short. 11 CONTROL In our lines, we can integrate equipment for the weighing and inspection of the cheeses. One could think of the presence of metal, faults or damage, foreign parts or other visual deviations such as stains in the coating.
This inspection can be carried out by means of a metal detector, an X-ray device or a visual inspection.
Our programme includes one in-line weigher. The operation hereof is integrated in the line control system. The cheese transport along the weigher is complete under control because of this. Only a transfer of the weighing signal is needed. This link prevents many disruptions and guarantees the reliability of the product line.Wecanalsointegrateweighersfromthirdpartiesintheline,eithertogetherwith thenecessarylabelling equipment including label check or not. The weighing systems supplied by us are calibration-proof. For the inspection of the cheeses on metal, other faults and/or damage, we can integrate checking equipment in the line.
The check can be carried out with a metal detector, an X-ray device, or with a visual inspection. With the metal detector, metal particles can be traced, whereas with the X-ray device other foreign particles can be traced as well. Furthermore, the pattern of cheese holes can be checked in this way. A vision system assesses the cheeses on previously set visual deviations, such as stains in or on the plastic coating, and damage to the cheese. If a pollution or deviation is detected, the respective cheese can be taken out of the line.
PARAFFIN COATING BANDING/LABELLING One of our specialities is paraffin coating. We make use of the latest techniques at that. We offer your fully automated paraffin coating solutions for the most diverse cheese types. You can choose for the conventional approach with a line paraffin coater, but also for robot technique with the so-called robot paraffin coater. The wax-coating solutions we offer can be supplied as stand-alone, but also as completely automated line solution. The cheese supply and/or conveying, including the desired packing, can be completely automated.
For wax-coating we offer the following solutions, depending on the desired capacity and the available space. Apart from the conventional line wax-coaters, we also supply the robot wax-coater. This is a solution based on robot technology whereby various colours and types can be processed. It furthermore requires a minimal floor surface. Thanks to the robot wax-coater, the wax-coating cycle can be set free and flexibly. For each cheese type, the most optimum result can be achieved. The solidifying of the wax on the cheese can be done with air or water cooling. The capacity can be tuned easily on the needs by using several cheeses at the same time.
Depending on the cheese type, its size and the wax type, the capacity amounts to 500 to 2,000 cheeses per hour.
For applying a decorative or supportive band and for the application of silk tissue labels, we supply various banding, labelling and re-cladding solutions Depending on the application, applying the bands and labels is done by means of cheese plastic or a glue solution. Our banding machines can be placed in line in front or behind the plasticising machine. Both hard and semi-hard cheeses can be banded fully automatically in this way. Depending on the setup and the wishes from you as our customer, a capacity of 700 to 1,800 cheeses per hour can be reached. For the application of a label on top a cheese, we supply special labelling machines which can process up to 2,400 cheeses per hour.
The label is spread out extra after it has been applied. Because of this, and because of the pressing with a bent sponge role, the label can be pressed tightly on the cheese. For covering the above actions are combined. On the top and bottom the cheese is provided with a silk tissue label and finished all around with an ornamental band. Both the labels and the band are applied on the cheese in wet cheese plastic, so that the chances of mould formation under the labels are limited to a minimum. The covering takes place in two steps. First a label is applied to the top. After the drying process, the cheese is turned in one turn, upon which the other side is labelled and the band is applied.
FRIESLAND CAMPINA STEENDEREN • volume packaging department Gouda cheeses • 4 Fanuc robots • box loading and unloading • wax-coating (2 types of wax) • packing and palletising • in line control functionalities • capacity: 1000 cheeses per hour FRIESLAND CAMPINA LUTJEWINKEL BOUTER KAASHANDEL GROOT-AMMERS • 2 maxi lines connected to a high-rise warehouse • delivery line connected to high-rise warehouse • delivery on transport boxes • separate delivery DOC KAAS • packing line for foil cheese • crate loading for foil cheese • maxi line connected to brine bath and high-rise warehouse • maxi-lijn connected to high-rise warehouse • delivery line connected to high-rise warehouse • 3 maxi lines including cheese reception • delivery system • re-boxing cheese • palletising cheese REFERENCES ROBOT PROJECTS Vandersterre groep • multi-functional cheese treatment installation • 2 Fanuc robots • re-boxing • banding and labelling • in line weighing • in crate loading and palletising • capacity: 500 shelves per hour A-ware Workum • 3 maxi lines • cheese reception • warehouse box unloading line • integration wax-coating line • transport box loading • palletising cheese in box • separate delivery 15 14
LOADING AND UNLOADING BOXES One of the first robot that was applied within the cheese industry in the Netherlands, was a robot for loading transport boxes. The use of robots for loading and unloading has since expanded enormously. We supply various systems for the unloading and loading of boxes. The unloading and loading of cheese boxes is still one of the most common applications of robots in the cheese branch. Whether it concerns transport or warehouse boxes: there is always a suitable robot available. Robots are reliable, flexible, and can be used multi-functionally. A robot can for instance process many box types and sizes, and it can turn the cheeses if desired before they are put on a transport belt or in the box.
They are also a great deal of freedom with regard to selecting the location where the cheeses are picked up and put down.
Robots can be used twenty-four hours a day. By applying robots when loading and unloading boxes, the problems regarding occupation health issues belong to the past. Depending on the shelf and box size, the desired actions as well as the setup, by means of a robot 250 to 600 shelves can be loaded or unloaded per hour. With one single system, cheeses can be unloaded both from crates and boxes, in order to enter them into de-rind and cutting lines. Ifacompletelystainlesssteelsolutionisrequired,wecanofferasystemwithastainle sssteelmanipulator. 17 BOX-TO-BOX A specific type of loading and unloading of boxes is the so-called box-to-box loading.
Cheeses are laid from one box type into the other at that. This system is suitable for many cheese types and box types, and can be used for the storage and removal from storage, but also for transferring internally to a different box type. By automatically loading and unloading boxes, the labour conditions are strongly improved. Trucks namely do no longer have to be loaded or unloaded by hand. Furthermore, cheeses must often be transferred from warehouse box to transport box and vice versa because of different box types. With our robot re-boxing solution we load cheese from a warehouse box easily into a transport box and vice versa.
The re-boxing unit can constitute a part of a complete cheese treatment line, or be applied as a stand- alone unit. The unit consists of a robot cell, possibly two turning platforms, one intermediate formation station, and the necessary controls. The system can also be expanded with a box buffer, so that you can work longer unattended. Because of this robot technology, you obtain more flexibility in the choice of the cheese types and box types to be processed. A robot is namely freely programmable and can thus carry out several actions.
By using a re-boxing unit, objections with regard to occupational health are no longer involved. 16
SMALL PACKING For transferring, depositing and packing various products and packing types, Kaasbehandeling.nl has a broad range of robot systems available. Robots can for instance aid you at removing the cheese from the cutting and portioning systems and take over the depositing in packing machines from you. For the packaging of products in cover boxes, display boxes, or crates we have developed various compact pick & place cells. The capacity of these cells is product and application dependent.
If necessary, several products can be picked up at the same time. Also, several robots can be placed in one cell. For all these applications we supply total solutions, made-to-measure, including supply and conveying systems, gripper systems, programs, et cetera.
Robots are quick, accurate, reliable, flexible, easy to implement in existing processes, require little maintenance, and are based on proved technology. We have extensive robot programs of well-known brands available, and therewith offer the option to think up the right solution for each application. We will be happy to discuss with you which efficiency turn you can make by using one of our robot installations for transferring, placing, or packing your products. 19 LARGE PACKING For the packing of complete cheeses we offer a number of solutions as well. Whether it concerns the large packing of Gouda cheeses (five and/or thirteen kilogram) in quadruple, octagon or in an American folding box, or packing in foil and/or cover box of rectangles: we have a tailor-made solution for you!
For bulk packaging of round cheeses we supply a complete cheese packaging line or, if desired, a part thereof. These lines can contain the following functionalities: taking the cheeses out of the box, wax- coating, possibly turning, banding, labelling, weighing, and packaging. After the desired functionalities have been carried out, the cheeses can subsequently be palletised. We supply the installations ‘turn-key’, complete with transport belts, transfer devices, box folding machines, robots, and other equipment. The capacity is tuned to the wishes of the customer. We also offer you solutions for packaging foil cheese in a cover box.
For the packaging in the box, we can supply various brands of box and lid placement machines.
FOIL PACKING There are various options for the vacuum packing of cheeses. The client, the cheese assortment, and the price level of both the packing machine(s) and the foil determine the choice. Usual packing materials include thermoform and shrink coating. The selected machines can be supplied by us and subsequently integrated in an automatically operating system. The vacuum packing of the cheeses can be done both in thermoform foil and in shrink foil. In a deep-pulling machine with thermoform, the foil is unfolded and shaped with a deep-pulling process.
A completely stainless steel pick & place unit places the cheese in the pre-shaped foil. The packing in shrink foil consists of the following steps: placing the cheese into a bag, vacuuming the bag and sealing it, and finally shrinking and cooling down de foil. Depending on the capacity and the weight of the cheese, the above steps can be carried out automatically or semi-automatically.
In the supply of the cheeses to the packaging machines, they are buffered and depending on the capacity of the vacuuming machines offered in batches. It is possible to combine several packing machines in one single line. After the packing, the cheese flows are combined. A flow-packer in combination with a vacuum unit can also be used for the packing of the cheeses. 21 LOADING AND UNLOADING CRATES Rectangular cheeses packed in foil are laid in crates for curing. After the foil cheeses have cured, they are removed from the crate for shipment or further processing. The capacity depends on the dimensions of the cheeses.
For so-called Euroblocks the maximum capacity amounts to 1,500 pieces per hour.
Foil cheese matures in crates. Because of this, it maintains its shape and the foil is protected against damage. In the conditioned storage, the crates can be stacked. Before a crate is filled, the robot removes the stacking rim. It subsequently places a cardboard plate on the bottom in order to prevent damage to and pollution of the foil of the bottom layer of cheeses. Between the layers, the robot can still place more cardboard or wooden plates if desired. It is important that the cheeses are put into the crate with as little play as possible. Because of this, the cheeses maintain their rectangular shape and the loss during cutting - the ‘slicing’ - is minimal.
After the final layer of cheeses has been put into the crate, the robot places the stacking ring on the crate and it can be conveyed. If desired, it is possible to stick a label with among other things the total weight, the cheese type and/or the production date on the crate. After maturing, the cheeses can be automatically taken out of the crate, weighed, and delivered with a crate unloading system. The delivery can among other things be to a large packaging line, a cutting line, or any desired stacking pattern on a pallet.
(DE)PALLETISING For the (de)palletising of among other things loose cheeses, foil cheeses, boxes and crates we supply tailor-made robot (de)palletising systems. Thereby we pay attention to the product to be handled, the palletising, the capacity and the set-up. The robot palletising systems address the characteristics compactness and multi-functionality. In this way, only a minimum of auxiliary equipment is needed. With a robot all imaginable cheese types, stacking patterns, and pallet types can be processed. In our systems, robots are often used for de-stacking empty pallets and placing intermediate sheets.
We have developed an extensive programme of (multi-)grippers for this. If the robot is used for different functionalities, it can be equipped with several grippers and a gripper exchange system.
Palletising installations are generally supplied on a ‘turn-key’ basis. The grippers, the product supply, and the pallet supply and conveying systems are designed client-specifically. The installations are in any case suited for your product and the application in the available space. Among other things, the installations are characterised by their high capacity (up to 1,200 cycles per hour), a huge handling weight (up to 1,200 kilograms), an unlimited amount of pallet sizes, endless options with regard to pallet stacking, options for placing empty pallets and an intermediate sheet, and simple operation.
22 23 ELTEN bv, formerly Elten Systems, started out in the 1970s and has since built up a renowned reputation with regard to the realisation of many mechanised projects. DERO bv is specialised in automating production processes by means of applying industrial robots made-to- measure.
©2012 DERO bv / ELTEN bv Nieuw Vennep (NL) +31 (0)252 622 500 email@example.com www.derobv.nl Nieuw Vennep / Barneveld (NL) +31 (0)252 625 718 firstname.lastname@example.org www.eltenbv.nl