Martin Čech, R&D project manager (right) with Marek Novák, flooring technologist (left)
Manually sealing cartons with tape – until 2024, this step was part of Fatra’s packaging process for LVT floor panels. But it was slow, physically demanding, and required a large number of employees. With a new packaging line, the Czech plastics processor has fully automated this step. Today, the cartons are sealed using a Robatech hot melt adhesive application system – quickly, reliably, and with almost no manual intervention.
From manually sealing with tape …
Fatra, headquartered in Napajedla in the Czech Republic, is a leading European processor of plastics such as PVC, PE, and PET. To further increase efficiency in the production of LVT flooring panels, the company commissioned the local machine builder Deprox s.r.o. to develop a new, automated packaging line. The goal was to combine several previously separate work steps into a continuous process – from processing the LVT floor panels to palletized packaging.
“Originally, we sealed the packaging boxes manually with adhesive tape, which was physically demanding, slow, and labor-intensive,” explains Martin Čech, R&D Project Manager at Fatra. “When planning the new line, it was therefore clear from the start that we wanted to fully automate this step.” In addition to automation, the switch from adhesive tape to hot melt adhesive also offered the advantage of lower material consumption. This led to a sustainable reduction in packaging costs.
… to an automated packaging line with adhesive application
The new system combines several process steps into a single automated line. First, the edges of the LVT floor panels are beveled; then the floor panels are stacked and packed in cartons. With a production speed of up to one LVT panel every two seconds, every process step has to work perfectly. Fatra therefore set clear requirements for sealing the cartons: The adhesive application system should not slow down the high production speed and must operate with absolute reliability.
The machine builder Deprox integrated an adhesive application system from Robatech, supplied and supported by its Czech partner KALETECH. At the heart of the solution is a Vision S adhesive melter combined with Performa heated hoses and three SX application heads. The system is designed for precise and uniform adhesive application, thereby meeting the requirements for high speed and process reliability. The hot melt adhesive is applied in bead form to the top and sides of the cartons – ensuring a reliable seal even at high cycle rates. “Just a few seconds after being sealed, the boxes are picked up by a robot and palletized,” explains Martin Čech. “If a box were to open, the panels would fall out. That’s why the adhesive has to adhere reliably right away.”
Efficient collaboration thanks to short distances
Fatra’s collaboration with Deprox and KALETECH was smooth and solution-oriented. A key advantage was their geographical proximity: all partners are located within a radius of about 30 kilometers. “The system programmer, the service technician for the industrial robot, and the KALETECH sales representative were all on site quickly,” explains Martin Čech. “This allowed us to resolve every issue personally within one to two days.”
After commissioning, the start of production went smoothly. The adhesive application system was delivered by KALETECH already preconfigured and required only minor adjustments during the fine-tuning of the line.
Stable adhesive application in operation
Today – two years later – the adhesive application system is still operating smoothly and reliably. “The adhesive application is 100 percent effective,” reports Marek Novák, flooring technology specialist at Fatra. “During operation, the only task is to regularly refill the granules.”
Apart from the material feed and refilling the adhesive, the entire process runs fully automatically. Overall, this has allowed the company to reduce its workforce by 16 employees, who have been reassigned to other areas.
The result: a fully automated packaging process that is faster, more resource-efficient, and significantly less labor-intensive than before.