Automated packaging of respirator masks

In order to be able to respond to the unexpected need for respiratory protection masks as quickly as possible, Breckle GmbH had to restructure its own production in a hurry. In the beginning, the masks were elaborately manufactured by hand. As demand increased, the company had developed the know-how and automated the mask production step by step. In addition to the fast delivery and low cost of the automation solution, the use of hygienic components for the production and packaging of respiratory masks is a priority. In addition, the available space in the production hall is limited, which is why the machines have to be as space-saving as possible. In order for the respirators to be certified as a German brand, the material for production is not purchased in China. Nevertheless, in order to keep up with the cost and hygiene standards of foreign manufacturers, Breckle relies on components from Low Cost Automation, among others, for its highly automated production and packaging.

Every week, four machines with approx. 20 employees produce around 100,000 surgical and FFP2 masks. Two fully automatic packaging systems based on the igus gantry system are used for the manual and automatic packaging of the masks. The masks, which have successfully passed the automatic quality control, are filled via a conveyor belt with the help of drylin bearings and shafts into the cardboard boxes, which are automatically provided by the gantry system. Driven by a flat toothed belt drive, the drylin gantries travel absolutely lubricant-free and fulfill high hygienic standards. For the entire robot kinematics, plant manufacturer Ximaj uses a B&R controller, which in turn communicates with a dryve D1 controller from igus to control the system's motors. With the introduction of the quality assurance system and the automatic packaging machines, the mask production could be reduced from three shifts to two. In addition to the time savings, there is also a high cost advantage. Automation solutions from LCA usually pay for themselves within one year. In addition, the tribologically optimized components are lubrication- and maintenance-free. With increasing demand for respirators, Breckle will continue to expand automated production in the future.

Gantry Planner