The converting industry plays a critical role in global manufacturing. Companies transform raw materials into products like plastic films, papers, foils, textiles, and fabrics, which are then rolled up for further processing and distribution. Virtually every type of product made uses the output of converting companies in some way.
The converting process is complex and can involve one or more of several actions, including coating, laminating, printing, drying, extruding, and slitting. All require precise handling and manipulation of thin, flexible materials. To manage that complexity, manufacturers increasingly utilize material handlers, lift-assist devices, and other specialized industrial manipulators. They have emerged as essential systems in the converting industry, enabling companies to increase efficiency, precision, and safety.
This article explores how industrial manipulators are tailored to benefit the converting industry.
Industry Overview
The converting (or converter) industry leverages a wide range of manufacturing processes that turn raw materials into usable products. These processes often involve manipulating materials in roll or sheet form (with or without center shafts), applying various treatments, and cutting or shaping them into the desired configurations.
Examples of converted products include:
- Labels and stickers
- Packaging materials, like plastic films and paperboard boxes
- Construction materials, such as roofing membranes, insulation, etc.
- Medical and hygiene products, including wound dressings, diapers, and many other items
- Automotive components, such as interior trim and airbags
Converting processes vary by material and end product but typically involve several steps. Some common actions include unwinding, treating, rewinding, and cutting. Careful handling and manipulation of materials are essential to prevent damage, ensure high product quality, and maximize process efficiency.
How Industrial Manipulators Are Used in the Converting Industry
Industrial manipulators are pneumatic machines designed to lift, handle, and move materials in a manufacturing environment. These systems typically have anchored bases, swiveling bodies, and articulated arms with various attachments that enable a broad range of motion to perform many types of tasks.
Industrial manipulators play a vital role in improving material handling operations in the converting industry. Workers use them to lift, rotate, position, and move materials with high precision and repeatability. These systems offer several key benefits, including:
- Increased safety. Material handling tasks can be physically demanding when performed manually, posing risks to workers of many types of injuries, from back strains due to heavy lifting to lacerations or broken bones from mishandled or dropped objects. Industrial manipulators can eliminate these risks by performing work as directed by a human operator who is out of harm's way.
- Improved efficiency. Industrial manipulators can perform tasks faster than workers, reducing cycle times and increasing production rates. They can also operate continuously without the need for breaks, helping manufacturers minimize downtime and maximize throughput.
- Enhanced precision. Converting processes typically require precise material handling to ensure product quality and avoid defects. Industrial manipulators can achieve high levels of accuracy and repeatability, minimizing errors and ensuring consistent product output.
Another crucial characteristic of these systems is their flexibility. Industrial manipulators can be programmed to perform various tasks, enabling manufacturers to adapt to changing production requirements and product specifications. They can also be moved to different workstations or production lines as needed.
How Tailored Industrial Manipulator Solutions Meet the Converting Industry's Needs
Manufacturers can use general-purpose industrial manipulators in their converting processes. However, they benefit more from systems customized to their needs and goals. Specialized industrial manipulator solutions offer several advantages, including:
- Optimized material handling capabilities. Converting processes often involve handling delicate or sensitive materials like thin films or fabrics. Material handlers and other industrial manipulators can be equipped with features like vacuum grippers, soft grippers, or magnetic grippers capable of handling these materials safely, securely, and without causing damage.
- Precise control. Operations in this industry often require material tension, alignment, and positioning within precise specifications. Specialized manipulators are outfitted with advanced control systems and sensors that enable them to achieve high levels of accuracy and repeatability in these tasks.
- Integration with converting equipment. Manufacturers can seamlessly integrate industrial manipulators with converting equipment, such as unwinding and rewinding machines, coating equipment, and slitting machines. This integration enables smooth material flow and efficient production processes.
- Task-specific setup. Each converting process has unique material handling requirements. Manipulators can be customized with features and functionalities to meet the needs of specific converting actions.
Manufacturers use tailored industrial manipulator solutions in a wide range of applications. Some of the most common functions include:
- Roll handling. Industrial manipulators can lift, rotate, and position heavy rolls of material, facilitating loading and unloading operations and transferring rolls between different workstations.
- Sheet handling. Devices can pick up and place individual sheets, enabling workers to feed, stack and sort materials with outstanding precision.
- Web handling. Industrial manipulators can handle continuous webs of material, such as films or fabrics, in processes like coating, laminating, and printing.
- Packaging. Companies can use these systems to load and unload products into packaging containers and perform tasks like sealing, labeling, and palletizing.
- Quality control: Manipulators can be equipped with vision systems or other sensors to inspect products for defects, ensuring quality and compliance with specifications.
Choosing the Right Industrial Manipulator for Converting Applications
Getting the most benefit from industrial manipulators requires implementing solutions that have the desired capabilities. When researching systems for use in converting processes, you should consider several factors, including:
- Payload capacity. The manipulator should be able to handle the maximum weight of the materials to be managed — ideally with capacity to spare.
- Reach. The manipulator's reach should be sufficient to cover the required work area and easily access the points farthest from its base.
- Speed and acceleration. The manipulator's speed and acceleration should suit the required production rates and cycle times.
- Precision. The device must have the accuracy and repeatability necessary to meet the requirements of the specific converting process.
- Control system. An industrial manipulator's control system should be user-friendly and easy to program and customize.
- Safety features. An industrial manipulator system must have advanced safety features, such as collision detection and emergency stop functions. These features are necessary to protect workers and prevent property damage.
- Integration capabilities. Devices should be compatible with converting equipment and be able to communicate with the overall production control system.
- Cost/benefit analysis. The cost of industrial manipulators can vary depending on their size, capabilities, and features. However, the long-term benefits of increased efficiency, productivity, and safety with the right systems will quickly exceed the initial investment.
Another essential factor to consider when implementing industrial manipulator solutions is their source.
Dalmec is a recognized worldwide leader in industrial manipulator solutions. When you work with our team, you benefit from our extensive experience in the converting industry, comprehensive service, and attentive support. From designing and implementing your ideal systems to providing guidance on training your workers and maintaining your devices, we're with you every step of the way.
Emerging Trends and Innovations for Industrial Manipulators in the Converting Industry
The converting industry is continually evolving, driven by advancements in technology and materials, changing consumer preferences, and the need for sustainable manufacturing practices. Industrial manipulators are playing a pivotal role in shaping the evolution of this industry, with several key trends underway and new developments on the horizon:
- Increased adoption of collaborative systems. Industrial manipulators are increasingly being designed to operate alongside human workers, sharing the same workspace safely and effectively while collaborating on tasks.
- Advancements in sensor technology. Integrating advanced sensors, such as vision systems, force sensors, and proximity sensors, will continue to enhance the capabilities of industrial manipulators. These sensors enable manipulators to perceive their environment, detect objects, and interact with materials more effectively.
- Increased focus on sustainability. As the converting industry (like all industries) strives to reduce its environmental impact, industrial manipulators can support sustainable manufacturing practices by optimizing material usage, minimizing waste, and reducing energy consumption.
Industrial manipulators are contributing to the converting industry in exciting ways. As technology continues to advance, we can expect to see these systems become even more sophisticated and capable, improving manufacturing processes and driving innovation in this sector.
By embracing emerging trends and investing in the latest industrial manipulator technology, converting manufacturers will position themselves for future success. They can look forward to higher levels of productivity, efficiency, and sustainability while meeting the evolving demands of the marketplace.
Final Thoughts
Customized industrial manipulator solutions offer many benefits to the converting industry. They enable manufacturers to operate faster, more efficiently, and with greater precision and safety. By streamlining material handling tasks, these systems can also increase production rates, reduce errors, and improve product quality.
As the converting industry continues to evolve and adopt new technologies, specialized industrial manipulators will likely play an even more fundamental part in their success.
If you have questions about our customized industrial manipulator solutions for the converting industry, please contact us at your convenience. Our experts are happy to discuss your business and operational objectives and explain how our systems can help you achieve them.
