Elettric80 and BEMA are totally changing the way of designing factories, offering the most efficient and safest solutions available worldwide.
Elettric80 and BEMA offer automation solutions for high volume consumer product companies, mainly in tissue, beverage and food sectors. The two companies specialize in the implementation of flexible, modular, integrated automation solutions which improve planning and control of production, storage and shipping activities.
The results are a significant increase in factory efficiency, total traceability of handled products, maximum safety and strong return on capital invested over many years.
The primary tools of the trade, designed according to the tissue customer’s needs are: a wide range of LASER GUIDED VEHICLES (LGVs); WOODPECKER pallet checking system, DRAGON high speed palletizer, SMARTBOX the compact end-of-line solution, SILKWORM stretch wrapper, ROBOTIC LABELLER and SMART STORE high density warehouses.
The whole process is managed centrally by a fully integrated software platform, named SM.I.LE80 (Smart Integrated Logistics), which ensures the optimal and effective management of all internal and external plant operations: from incoming raw materials to complete warehousing and shipping.
Thanks to highly innovative hardware and software solutions, Elettric80 and BEMA revolutionized Factory 4.0 more than 20 years ago, becoming well-known all over the world as the market leader of integrated automation solutions.
As a compliment to their innovative solutions, Elettric80 and BEMA guarantee their worldwide business customers a 24/7 remote and on-site assistance and support service which ensures them to remain highly efficient over time. In fact, Elettric80 and BEMA technicians work around the clock within the two companies’ Customer Service and Support Centers. For larger, more complex systems, Elettric80 and BEMA can deploy Embedded Engineerswith the aim of guaranteeing efficiency to the plants proposed over time. All technicians are engaged in continuous training programmes, assisting testers in the workshop; thus, they all are constantly updated on the technological innovations that will be implemented in the customer’s plants.
The Hardware Solutions Implemented
ELEPHANT LGV system for parent reel transport and warehousing helps customers to achieve higher line uptime, paper waste savings and more safety.
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WOODPECKER pallet control automatic system ensures that only pallets complying with the customer’s requirements are used in the manufacturing process. It prevents problems in production, during the handling, damage to finished product as well as inside the automatic warehouses.
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DRAGON robotic palletizer, for high speed applications, is designed to allow packs, bundles and cases to run at high speed on the same line with ZERO product change time. It is at floor level, flexible and efficient on all types of products.
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SILKWORM robotic stretch wrapper, thanks to the use of the 1000-mm high film reel, the robotic technology and the motionless wrapping head, guarantees high production speed. Furthermore, it ensures maximum flexibility, allowing the stretch wrapping of pallets with different dimensions, while preserving the same quality and the product integrity as well as ensuring load stability.
SILKWORM has been designed to reduce the reel replacement frequency and the operator’s interventions, guaranteeing the reel automatic changeover without interruptions along the production line. The system is a stand-alone, which increases the production line efficiency.
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The ROBOTIC LABELLER is equipped with an anthropomorphic robot that enables to apply labels on more sides and levels, guaranteeing production flexibility and high speed in limited space. The applicator arm is equipped with a telecamera to check the correct application of labels and the barcode readability. The option with two printers allows to double the operational autonomy and carry out the automatic reel changeover without any production downtimes, thus uncreasing the line overall efficiency.
Maximizing warehouse efficiency, space and energy savings is possible with SMART STORE, a high-density warehouse designed to meet the customers’ automatic storage and retrieval requirements, including shipping efficiency, optimization of warehouse density and fill factor.
SMART BOX
The compact end-of-line solution: unique, robust, modular, and extremely efficient; easy to use and maintain.
Elettric80 and BEMA have designed and implemented an innovative system for the tissue industry that integrates the best technologies of both companies.
Within the space of only 12m x 7.5m, the SMART BOX combines palletizing, wrapping, and labelling in a flexible and compact layout.
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The SMART BOX system -- easy to use and maintain -- offers multiple advantages, such as high efficiency, close-couple to production lines, and low maintenance costs that remain constant over time thanks to the limited number of mechanical components. The implementation of SMART BOX has also made it possible to improve the performance of the robotic labeller, consolidating a new range of products and developing a very compact and simplified product-input management, ideal for medium outputs.
The SMART BOX concept has already demonstrated that it can be applied not only in the tissue sector but also in other sectors, with positive long-term effects on the entire production line.
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Successful Case Studies
Roto-cart S.p.A. : Fully Integrated Tissue Converting Facility
Roto-cart S.p.A. is a top quality integrated tissue producer, manufacturing toilet rolls, kitchen rolls, napkins and AFH products. All premium products are distributed through the brands Sensitive and Toffly for consumer market and Formula for away from home. The Company produces parent reels in the Group’s mill base in Borgo a Mozzano (Lucca) and converts them into finished goods at the completely new 48,000 m2 manufacturing, storage and distribution facility in Castelminio (Treviso). In addition, the Company operates a second converting plant in Piombino Dese (Padua Province), actually Group’s HeadQuarters.
The Group currently supplies some of the Italy’s largest retailers and wholesalers (2.7% market share of Italian market). The Group currently has 11 converting lines in operation, which include 5 recently commissioned lines (including the most advanced 900 meters/min Perini Print Unit equipped with all carbon rollers) for the completely new plant in Castelminio (this plant represents the state of the art in terms of integration and flexibility in the tissue market). For its new cutting-edge converting facility, Roto-cart S.p.A. chose Elettric80 and BEMA as sole partner in the establishment of one of the main greenfield production facilities. This is another important example of a fully integrated factory, from raw material input, scheduling of production and related processes, palletizing, stretchwrapping and warehouse management, full interaction with the client's ERP system, to finished product preparation for truck loading. The group decided to entrust Elettric80 and BEMA with an investment of over 20 million euros.
Sofidel: From Smart Factory To Smart Revolution
Sofidel boasts a net sales of more than 1,7 billion Euros (2017) and a worldwide presence. In an assertive and dynamic manner, Sofidel has internationalized its business efficiently, analyzing its manufacturing plants individually; it has reached this aim by relying on a technological and strategic approach for optimizing costs and the quality of solutions. Sofidel’s latest project is a greenfield plant built in Ohio, for which the Italian investors were congratulated by former US President, Barack Obama in 2016. It is an outstanding 4.0 factory which is highly automated and integrated, from the raw materials to the truck loading: an overall investment of over 330 million Euros, 30 of which the Group decided to entrust to Elettric80 and BEMA.
The greenfield converting plant, opened in Sweden in 2015, gives an idea of the magnitude of the project currently being implemented.
Papelera San Andres de Giles: 20 Years Betting On Innovation
With an emphasis on high product quality and service, Papelera San Andres de Giles (PSAG) has consistently bet on technological and product innovation. Considered Argentina’s most efficient and modern tissue manufacturer today, it’s fair to say those bets have paid off. In 2016 PSAG was internationally recognized with the prestigious PPI Tissue Innovation Award, honoring its Leadership, Vision, Innovation and Strategic Accomplishments. Step by step, over the years, all production processes have been integrated and fully automated. Starting from the automated LGV-managed parent reel warehouse and flowing through to robotic palletizing, robotic stretch wrapping, LGV pallet transport, the 5-level high 10,000-pallet position LGV automated drive-in warehouse, automatic LGV pallet pre-staging, and the newly constructed self-supporting Smart Store high-density warehouse, 7-levels high housing 16,000-pallet positions. Papelera San Andres de Giles and the Gagliardi family selected and entrusted Elettric80 & BEMA for every step along the way.
