VERSION CONTROL

VERSION DATE CHANGES DONE BY CHECKED BY APPROVED BY

Raúl Benítez Estefanía Garrido François van Rooij
1.0 04/10/2020 New Procedure LELYSTAD LELYSTAD LELYSTAD
PLATFORM PLATFORM PLATFORM

BOX MAKER
MAINTENANCE
PROCEDURE A5
A1-PED-PAQ-015
V1.0
 A1-PED-PAQ-015
BOX MAKER Date: 04/10/2020
Version: 1.0

Index
1. OPERATIVE / FUNCTIONALITY.................................................................................................................................................. 2
2. PROCEDURE REVISIONS.......................................................................................................................................................... 7

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 A1-PED-PAQ-015
BOX MAKER Date: 04/10/2020
Version: 1.0

1. OPERATIVE / FUNCTIONALITY

Lantech box maker assembles the boxes from flat cartons that the operators load into the magazine. It is also responsible for sealing the
boxes at the bottom using hotmelt glue (bottom tape module deactivated). The box maker (Id. 20184616) that is used for the order
preparation in flat pack area is located on the third floor (Empty box area).

The sequence of operations for box assembly by box manufacturer Lantech starts with the blanks in the loader and follows the blanks
through the folding and sealing sections.

1) The pickup frame moves the suction cups to the blank and holds the blank with vacuum.
2) The blank opens as the pickup frame retracts to the home position.
3) The inner flaps fold.
4) The outer flaps start to fold.
5) The suction cups release the case.
6) The pickup frame retracts.
7) The pusher arm moves the case to the side belts.
8) The side belts move the case over the sealing section.
9) As it moves through the side belts, the nozzles on the glue gun apply hot glue to the outer flaps.
10) The upper compression plate lowers and the lower compression plate raises. The plates close the outer flaps over the inner
flaps to seal the bottom of the case.
11) The compression plates move to the home position.
12) The side belts move the case through the sealing section where it applies the tape and seals the case.
13) The case moves from the Case Erector.

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 A1-PED-PAQ-015
BOX MAKER Date: 04/10/2020
Version: 1.0

☐ STEP 01 Main components of the box maker are:

1. Pusher Arm – Pushes the case to the sealing section

2. Pickup Frame – Opens the blank
3. Flapfolders – Folds the blank flaps
4. Inner Flapfolder
5. Glue gun – Applies the glue to the bottom flaps.
6. Compression Plate – The plate that closes the bottom flaps.
7. Sealing Section – Seals the bottom flaps of the case
8. Operator Controls
9. Magazine – Holds the blanks
10. Hotmelt Unit - Melts the glue and keeps it at the correct temperature.
11. Electrical cabinet – Includes the control devices (Relays, Fuses/Circuit Breakers,
Wire Terminals, Logic Control, Disconnect switch)

☐ STEP 02 The orange components allow the machine to quickly adjust to the dimensions of the boxes
when changing the format or size of the boxes.

1. Magazine Height (HMI)

2. Handwheel 2 – Inner Flap Length
3. Handwheel 3 – Outer Flap Length
4. Upper Separator
5. Handwheel 5 – Case Length
6. Handwheel 6 – Side Belts
7 - 8. Suction Cups
9. Speed (HMI)
10. Compression plate
11. Upper box limit
12. Front Flapfolder

☐ STEP 03

The MAGAZINE holds the blanks and supplies the next blank for the pickup frame. The belts
pneumatically move the next blank into position.

The height of the charger can be adjusted via the control panel.

☐ STEP 04

The PICKUP FRAME extends to the magazine to hold a blank and then retracts to open the
blank. It holds the blank as the flaps fold.

The pickup frame uses the vacuum on the suction cups to hold the blank.

The pickup frame has a hinge that opens the blank. It also keeps the suction cups in touch
with the blank while it folds.

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 A1-PED-PAQ-015
BOX MAKER Date: 04/10/2020
Version: 1.0

☐ STEP 05

The FLAPFOLDERS FOLD the inner flaps (1) and the outer flaps (2). The inner flaps fold,
then the outer flaps start to fold.

The PUSHER ARM (3) then moves the case to the sealing section.

☐ STEP 06

The side belts move the case over the SEALING SECTION. As it moves through the side
belts, the nozzles on the glue gun applies hot glue to the outer flaps.

This machine can also seal the boxes at the bottom with adhesive tape, but it is not used in
our plant.

☐ STEP 07

The side belts move the case over the SEALING SECTION. As it moves through the side
belts, the nozzles on the glue gun applies hot glue to the outer flaps. The compression plates
close the outer flaps over the inner flaps to seal the bottom of the case.

☐ STEP 08

The HOTMELT UNIT sucks the glue pearls contained in the storage container through a duct
(Venturi effect).

Once the heating process starts, the Robatech unit starts heating the tank, hose and nozzles
to their set temperature.

Once the device is ready for operation, it pumps the melted adhesive through a heated hose
and directed to the bottom flaps of the box by means of two nozzles.

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 A1-PED-PAQ-015
BOX MAKER Date: 04/10/2020
Version: 1.0

MEANING OF THE BEACON COLOURS

☐ STEP 01

RED light: If it flashes, there is a general failure.

ORANGE light: If it flashes, the hotmelt unit is almost empty.

White light: The tape unit is almost empty when it flashes and is empty when stays on. Also
when white light stays on the tape is broken (tape module not used in our plant).

Blue light: The magazine is almost empty when it flashes and is empty when stays on.

Green light: If it flashes, the machine is in “Standby” mode.

BOX MAKER CONTROL PANEL

☐ STEP 01

Press the F4 button to access the "Operator Options Menu" where you will find different sub-
menus to configure box maker machine multiple options:

 Adjust the Magazine

 Speed Selection
 Production Counters
 Run Mode
 Alarm History
 Hotmelt State
 Seal Type Selection
 Display Setup

HOTMELT UNIT CONTROL PANEL

☐ STEP 01 1. LEDs showing the current operating status.

2. LEDs showing the selected heating zone.
3. Selection keys for the heating zone and heating zone number (if more than 1 heated
hose/head). LCD showing the heating zone number.
4. Selection keys for the program functions and the operating parameters. Light display
of the selected function.
5. LCD showing the value for the selected function or parameters in field 4. LEDs with
the units of measurement. Selection keys to alter the values.
6. LCD showing code for unit status, parameter number or current day of the week.
Light display of the selected function. Selection keys to alter the values.
7. For activating and deactivating temperature lowering function
8. For activating and deactivating timer function
9. Reserved control panel for optional AS IK 40/AS IK 10 pattern controls; see the
relevant instructions.
10. Reserved control panel for pump control.

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 A1-PED-PAQ-015
BOX MAKER Date: 04/10/2020
Version: 1.0

MAINTENANCE

☐ STEP 01 BOX MAKER DAILY MAINTENANCE:

 Make sure that the safety curtains are attached to prevent access during operation.
 Examine the bearings for wear and listen for unusual noise during operation.
 Examine the electrical cable and air hoses for wear.
 Examine the door safety switch for damage.
 Examine the magazine belts, side belts and suction cups for wear.
 Make sure that the pneumatic supply is set correctly. Make sure that the air supply
filter is free from water.
 Look for air leaks.
 Make sure that the vents on the motors are clean.
 Clean the photoelectric sensor lenses and the reflectors.
 Remove the debris from in and around machine.
 Examine, adjust the Pusher arm to make sure that it is level. (Figure 7.2)

☐ STEP 02

BOX MAKER MONTHLY MAINTENANCE:

 Examine the motor bearings for wear.

 Clean the guides, shafts and screws with non-petroleum solvent.
 Make sure that the motors and fans are clear of dirt and debris.
 Examine, replace the blade on the tape head.

☐ STEP 03

HOTMELT UNIT MAINTENANCE:

Soiling and deposits in the adhesive system are the most common reason for malfunctions.
Therefore, the entire system has to be kept clean at all times and it is essential that the
maintenance tasks are carried out.

The maintenance intervals apply to one-shift operation. If the system is being used more
heavily than this, the frequency with which maintenance tasks are performed will need to be
increased accordingly.

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 A1-PED-PAQ-015
BOX MAKER Date: 04/10/2020
Version: 1.0

2. PROCEDURE REVISIONS
REVISIONS

Date Version Section Step Comments Validated by

04/10/2020 1.0 New Procedure Estefanía Garrido

APPROVAL

Date Version Section Step Comments Validated by

04/10/2020 1.0 New Procedure François v. Rooijen