Star philosophy is to create automated systems with highly accurate positioning, designed to reach the fastest cycle time using our standard robots. We use components adopted on our Group’s large-scale production: standard robots, only one controller capable to manage the whole automation, EOAT components, everything made by Star.
Star automation Europe has been manufacturing IML automation systems since 1995. The long experience in this important field has driven Star to develop more and more flexible and high-performing solutions. IML applications, which are mainly used on food containers produced by 2, 4, 8 and 16 cavity moulds, are normally performed by two models of side entry robots, namely the TZ-1500HM and S7 Flex. Star has also reached important results in other sectors where IML is required: paint containers are just one example that shows how a side entry robot can be used in place of a vertical entry robot, like the XW-VI or Fx model, depending on specific cycle requirements.
We propose you two solutions:
IML with Side Entry robot
S7 Flex IML System:
This automation system features 7 servo driven axis for the whole management and handling of moulded products and labels. A single Stec-520 control system, which can manage up to 8 servo driven axis, controls the entire system. It features a colour touch-screen display for easy and free programming of the sequences. The main characteristic of our S7 Flex automation system for IML is its flexibility, as it can manage a number of significantly different processes (up to 999!) and allows the operator to switch from one process to another in just a few minutes. Thanks to its wide strokes these applications can be installed beside IMMs with clamping force between 200 and 750 tons. All dimensions, times and programs can be recorded, as all movements are carried out by servomotors; this makes production changes considerably easier and ensures higher quality and accuracy. A series of options completes this system and makes it ideal for cleanroom use.
A compact side-entry robot is the most suitable solution for simple application and moulds with a low number of cavities and products with small dimensions.
IML using TOP-ENTRY robot
This is a really flexible solution for applications with cycle time >8 sec, used mainly for large size products. The open mould daylight is very little and standardised components are used as much as possible.
Two vertical arms option is also available. The set-up time for production change is very short, so that the quantities of production is optimised.
The necessary attention that needs to be put into the non-contamination of products, their traceability and the need to reduce space during transport made Star develop turnkey automation systems specifically designed for the cutlery market and that guarantee high efficiency and reliability. Several systems designed in the last years provided Star Automation with the necessary experience to develop three standard solutions for moulds from 8 to 96 cavities. Automation systems for disposable cutlery offer the user the possibility to have a finished packet with the cutlery wrapped in transparent PP film and with a number of sets varying from 20 to 100 pieces.
Star is also specialised in automation solutions for disposable cutlery. We developed Top Entry and Side Entry robotic systems for Cutlery Automation which combine with 6 axis robotic systems.
We propose you three solutions:
Top Entry solution
IMM = 150 ÷ 850 tons
Robot: Fx Series
Small Side Entry solution
IMM = 100 ÷ 300 tons
Big Side Entry solution
IMM = 200 ÷ 750 tons
When particularly complicated handling, like after-moulding activities on the moulded item, is required, six-axes robots with 4 or 6 degrees of freedom find their ideal use. Thanks to their high flexibility, these robots can replace manpower in hard or dangerous operations, and Star Automation Europe can integrate six-axes robots supplied by some of the major manufacturers like Fanuc or Stäubli, install them and provide training to personnel.