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Objectifs du client

\n

TC Brød ApS, boulangerie industrielle dont le siège est situé à Grindsted, au Danemark, a récemment réalisé d'importants investissements en matière d'équipement, ce afin d'accroître son automatisation et sa capacité. Un élément clé de cette initiative a été la mise à niveau de son étuve en spirale, à l'origine de certains problèmes.

\n

La solution précédente de TC Brød faisait appel à deux spirales (l'une destinée au levage, l'autre à l'abaissement) pour acheminer les viennoiseries danoises. Les viennoiseries, encore crues et composées d'une grande quantité de beurre, sont très fragiles et particulièrement sensibles aux mouvements brusques. Le principal défi consistait à transférer les viennoiseries d'une spirale à l'autre : pour éviter d'endommager les produits, il convenait de limiter volontairement la vitesse du tapis et la quantité de produits transportés. En outre, la pâte beurrée produisait de la graisse, laquelle migrait vers les tambours des spirales et soulevait le tapis. Pour se prémunir contre ce problème, TC Brød nettoyait les spirales plusieurs fois par semaine. Le soulèvement du tapis et les nettoyages fréquents donnaient lieu à de longs arrêts imprévus qui mettaient en péril la production.

\n

Intervention d'Intralox

\n

Brød TC avait besoin d'une solution de tapis en spirale qui permettrait non seulement d'améliorer le rendement sans endommager les produits, mais aussi de réduire ou d'éliminer les temps d'arrêt imprévus. La société s'est associée à un fabricant d'équipements ayant recommandé une solution innovante, composée de deux tambours, d'un tapis et du système DirectDrive (DDS) Intralox.

\n

Le système d'entraînement breveté de la solution DDS emboîte les bords du tapis directement sur le tambour pour réduire les frais de maintenance et de nettoyage tout en optimisant le temps de production. Pour assurer la protection des applications, le DDS :

\n\n

De plus, l'utilisation d'un seul tapis fonctionnant avec deux spirales permettrait à TC Brød d'éliminer la zone de transfert, ainsi que toutes les détériorations des produits qui y sont liées.

\n

Résultats

\n

Depuis son installation en septembre 2016, la solution à double tambour DirectDrive a surpassé les attentes de TC Brød. La capacité du système DDS à aligner correctement les produits, ceci sans aucun transfert, a permis de ne plus les endommager. La solution DDS de TC Brød fonctionne à une vitesse supérieure à celle des spirales précédentes tout en acceptant une plus grande charge de produits.

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Parce que le système fonctionne même si de la graisse migre vers le tambour, le tapis ne se soulève plus. TC Brød nettoie désormais l'étuve une fois par semaine selon un calendrier cohérent et prévisible. Depuis, les responsables de l'usine n'ont souffert d'aucun temps d'arrêt imprévu et peuvent à présent mobiliser moins de travailleurs sur cette zone durant chaque période de travail. Combinée aux autres mises à niveau de l'usine, la solution à double tambour DirectDrive a permis d'améliorer considérablement le rendement de TC Brød. L'usine produit désormais 10 fois plus de produits qu'auparavant.

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