Today's flooring has to do more than look good. It also has to be resilient, insulated against footfall noise and not too expensive. Classen Industries in Baruth, Brandenburg, Germany, produces laminate flooring panels that meet these standards. They produce up to 65 million square meters of laminate a year in one of the fastest facilities in the world.
The new production line 7 alone delivers 60,000 to 70,000 square meters of panels -- per day. The manufacturer is consciously upgrading its production lines so that it can continue to compete effortlessly with East European rivals. In a joint effort with system constructors Wächter Packautomatic and SEW-EURODRIVE, Classen is reducing fixed costs in production through extremely high unit quantities.
This is how it works: The entire packaging line is controlled using Movi-PLC motion and logic controllers from SEW-EURODRIVE. A total of three MoviPLC-Advanced controllers and 25 servo drives are at work here. The first SEW motion controller regulates the production line 7 cycle and transmits this to all the connected Movi-PLCs via the CAN-based SEW system bus. Based on the SEW software, every motion controller calculates specific travel profiles that are synchronously transmitted to the relevant axes. This ensures that every drive in the axis system works synchronously and the speed automatically adapts to the lead speed. As a result, the panels are processed carefully, despite the high speed. Every single part is examined by camera, and only perfect panels of fiberboard and melamine resin are packaged. At a range of places in the packaging and production process, drive technology from SEW-EURODRIVE -- in this case, for example, a DR series gearmotor -- is ensuring that everything runs smoothly.
For Classen, a new system has to perform ten to twenty percent better than its predecessor. On production line 7, this means 270 laminate panels leave the belts each minute -- that's more than four parts a second. In the profiling system, they receive a groove and tongue for easy assembly, then it is on to quality control, into the boxes and finally onto the pallets. Each of these carries enough panels to cover approximately 150 square meters of floor. The Baruth plant lies 70 kilometers south of Berlin and is one of the largest laminate plants in the world. Production runs around the clock.
The flooring manufacturer therefore appreciates the reliability of SEW components. Many improvements keep energy consumption constant, despite much quicker production, for example energy efficient synchronous drives, regenerative power equipment and using smaller drives. In this way, the technology from Bruchsal is in keeping with the company philosophy of Classen in Brandenburg -- sustainable production at a constant, high level of competitiveness.
For more information about the company, please see:
https://www.sew-eurodrive.de/home.html
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servo drives wiki Laminate Flooring Panels | Classen Industries (english) | SEW-EURODRIVE | |
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