Automated Intralogistics in Packaging Production
Pallets equipped with RFID for Intralogistics
RFID-Controlled Logistics
Production at Casimir Kast comprises four stages: Printing, corrugated board production including laminating the printed sheets onto the corrugated board, die cutting and adhesive bonding. After lamination, the pallets with the products are transported via conveyor belts, RFID-enabled pallet flags are used to clearly identify which further steps take place, all the way to preparation for shipment to the customer.
The information on the RFID chip is read along a conveyor belt. Before shipping, the RFID flags are used to determine how each pallet must be packed. This is done automatically, after which the pallets are made available for collection.
Foils over the pallets make barcode reading difficult
In 2007, Casimir Kast planned to expand the production area by converting a hall, including the expansion of internal logistics with conveyor belts. In order to prepare pallets with manufactured packaging for shipping, the pallets have to be strapped with belts, and stretch film is applied over them.
Printed pallet flags are attached to the front of the pallets for unique identification. The biggest challenge in this process was that the barcodes of the pallet flags under the film could not be read correctly by the laser technology originally used, since the film refracts the light. This led to the decision to use RFID technology internally.
Production Process Automated with RFID Pallet Flags
Today, two pallet flags are created per pallet: One with RFID paper, and the other with plain paper. Both pallet flags have a barcode, which is also used by the carriers to identify the goods in the later stages of the supply chain. At Casimir Kast, the pallets of goods are placed on a conveyor belt that transports them internally to the individual production stages and to internal shipping.
RFID readers are placed along the conveyor belt to read the information from the RFID pallet flags, i.e., which route a pallet takes internally or how a pallet must be packed. By means of unique identification, it is possible to differentiate between goods ready for shipment and goods for further internal processing. The latter are discharged via a diverter, while the pallets with finished goods are automatically prepared for shipping.
RFID-controlled Intralogistics through to Shipping
Ultimately, all pallets ready for shipment are picked up from the conveyor belt by a forklift and loaded into a truck bridge that is standing by. RFID readers are again installed at the entry to the bridges, which signal the green light once it has been identified that this is the correct truck for the pallet. This ensures that there are no errors during loading.
From Casimir Kast, the pallets go to the warehouses of the carriers, from where they are delivered to the customers. Throughout the entire process, RFID technology guarantees process reliability, so that the right pallets always reach the right customer at the agreed time.