Operation of Machine
Sub-Assemblies Introduction
1. Shipper Magazine Assembly
1.1.3D Model
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Product Contact Parts - SS304
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Product Non-Contact Parts - MS, RAL 7045
Shipper Magazine
1.2 Shipper Magazine Assembly Operation
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All shippers are stacked vertically into the magazine, and are accessed through a front opening called the picture frame.
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The assembly consists of a sensor that detects whether there are enough shippers stacked. If the stack is low, an alarm is generated to alert the operator.
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The magazine is motor-driven, which ensures that the shippers are always pushed forward from behind. This maintains consistent pressure, allowing each shipper to move toward the picture frame for every pluck operation.
1.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
1.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
1.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
1.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
7.
8.
9.
10.
11.
13.
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
12.
14.
1
1
1
2
2. Shipper Plucker Assembly
2.1.3D Model
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Product Contact Parts - SS304
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Product Non-Contact Parts - MS, RAL 7045
Shipper Plucker Assembly
2.2 Shipper Plucker Assembly Operation
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The Shipper Plucker Assembly is a vacuum-based Plucker assisted by a servo mechanism.
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The Plucker grips the front surface of the shipper at the picture frame and then plucks it out using the servo.
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After plucking, the shipper is formed and positioned over the flap folding assembly, where the flap folding operation is performed on the carton with the inserted shipper.
2.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for Plucker assembly.
2.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
2.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
2.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
1
1
1
1
18.
19.
20.
21.
22.
2
5
1
1
4
1
1
1
3
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
23.
1
3. Flap Folding Assembly
3.1.3D Model
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Product Contact Parts - SS304,
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Product Non-Contact Parts - MS, RAL 7045
Flap Folding Assembly
3.2 Flap Folding Assembly Operation
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The Flap Folding Assembly is used for folding and tucking the the bottom flaps of the shipper doe the subsequent sealing with tape.
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It consists of three cylinders that close the two minor flaps and one major flap of the shipper, which operate after the shipper has been -plucked and formed properly.
3.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for Flap Folding assembly.
3.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
3.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
3.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
7.
8.
9.
10.
11.
12.
2
2
2
2
1
1
1
1
1
1
12.
4. Bottom Taping Assembly
4.1.3D Model
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Product Contact Parts - SS304,
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Product Non-Contact Parts - MS, RAL 7045
Bottom Taping Assembly
4.2 Bottom Taping Assembly Operation
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The Bottom Taping Machine is used for sealing the bottom of the shipper after the flaps have been folded in the flap folding assembly.
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The shipper is fed into the taping machine by a pusher from the flap folding assembly. It is then guided and moved by two side conveyors, which are motor-driven to ensure smooth and consistent transport through the taping head.
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The taping head mechanism applies the tape to the bottom of the shipper, sealing it completely.
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The PE sensor is present at the tape roll, where the presence of the tape roll is detected. If empty, it gives feedback to generate the alarm.
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After sealing, the shipper is transferred to the hopper assembly via a roller conveyor, ready for further handling or packing.
4.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for Bottom Taping assembly.
4.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
4.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
4.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
7.
8.
9.
10.
11.
12.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5. Hopper and Main drive Assembly
5.1.3D Model
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Product Contact Parts - SS304,
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Product Non-Contact Parts - MS, RAL 7045
Hopper Assembly
5.2 Hopper and Main Drive Assembly Operation
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The Hopper and Main drive Assembly is used to receive shippers from the Bottom Taping Machine and position them correctly for the next operation.
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It consists of a hopper that temporarily holds the shipper, and a cylinder that descends the hopper into the top open cylinder for precise placement.
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Two additional cylinders act as stoppers — one at the hopper and one before it — functioning as an indexer to control the shipper’s position accurately.
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Another cylinder at the hopper pushes the internal cylinder into the correct position under the hopper, ensuring the shipper is ready for the robot operation.
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After the robot places the matrix, the shipper is transferred smoothly to the Top Taping Assembly for the final sealing operation.
5.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for main drive assembly.
5.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
5.5 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
1
1
1
1
1
1
1
1
1
1
1
19.
20.
21.
28.
22.
23.
24.
25.
26.
27.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
29.
1
Belt
30.
5.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
6. Top Taping Assembly
6.1.3D Model
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Product Contact Parts - SS304,
-
Product Non-Contact Parts - MS, RAL 7045
Top taping Assembly
6.2 Top Taping Assembly Operation
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The Top Taping Assembly is used to seal the top of the shipper after the matrix has been placed and the shipper is positioned from the Hopper Assembly.
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The assembly consists of cylinder mechanisms that fold and close the top major and minor flaps of the shipper before the tape is applied.
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A photoelectric sensor at the start detects the presence of the shipper to ensure the operation only begins when a shipper is correctly in position.
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Another sensor is mounted near the tape roll to detect if the tape is running low or has run out, providing an alert to the operator and preventing incomplete sealing.
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Once the flaps are folded and the tape is applied, the shipper is completely sealed and ready for further handling or packing.
6.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for Top Taping assembly.
6.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
6.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
6.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
1
1
1
1
1
5.
1
7. Infeed Assembly
7.1.3D Model
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Product Contact Parts - SS304,
-
Product Non-Contact Parts - MS, RAL 7045
Infeed Assembly
7.2 Infeed Assembly Operation
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The Infeed Assembly is used to receive products from the upstream process and position them correctly onto the infeed conveyor.
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Products are tilted and placed on the conveyor using a pneumatic and vacuum-based mechanism to ensure proper orientation.
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The conveyor is equipped with cylinders and sensors that detect the products and help form a matrix on the coalition platform.
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The sensors also provide feedback to indicate when the conveyor is completely filled with products, ensuring smooth flow and proper timing for downstream operations.
7.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for Infeed assembly.
7.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
7.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
7.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
1
2
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1
1
1
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2
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1
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2
17.
8. collation Platform Assembly
8.1.3D Model
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Product Contact Parts - SS304,
-
Product Non-Contact Parts - MS, RAL 7045
collation platform Assembly
8.2 Collation Platform Assembly Operation
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The Collation Platform Assembly is used to form the product matrix for the robot to pick and place into the shipper.
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It is a servo-based assembly, which allows precise positioning and handling of products on the platform.
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The matrix configuration can be easily changed according to the product coming from upstream by loading the correct SKU or recipe in the HMI system.
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Once the matrix is formed, the assembly sends a signal to the robot, indicating that the products are ready to be picked and placed into the shipper.
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This ensures that products are correctly aligned, spaced, and synchronized with the robot operation, enabling efficient and accurate pick-and-place without errors.
8.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for coalition assembly.
8.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
8.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
8.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
2
2
2
2
1
1
1
1
1
1
1
18.
19.
20.
9. Robot Pick and Place Assembly
9.1.3D Model
-
Product Contact Parts - SS304,
-
Product Non-Contact Parts - MS, RAL 7045
Robot pick and Place Assembly
9.2 Robot Pick and Place Assembly Operation
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The Robot Pick & Place Assembly is responsible for picking the product matrix from the Coalition Platform and placing it into the shipper.
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The robot is equipped with a servo-based pick head, which ensures precise gripping and handling of products.
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The pickhead configuration can change according to the product or matrix, by loading the correct recipe in the SCADA or HMI system.
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Once the Coalition Platform signals that the matrix is formed, the robot picks the products and places them accurately into the shipper, ensuring alignment and proper orientation for subsequent operations.
9.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for Robot Pick and Place assembly.
9.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
9.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
9.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22,
23,
24,
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10. Guards Assembly
10.1. 3D Model
10.2 Guard Assembly Operation
-
The guard assembly ensures the safety of personnel during the operation of the machine
10. 3 Spare Parts
Note: Click on the Description for details about Spare parts
3.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
5.
5
5
5
10
10
10
8.
6.
7.
9.
10
2
10
Electrical Spares
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6.
7.
8.
9.
10.
11.
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13.
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26.
2
2
1
1
5
5
5
5
5
2
2
2
10
2
2
2
2
1
1
M12 Sensor cable 10M, XS5F-D421-J80-F
2
2
2
2
2
2
2