Automation · Robotics · Line simulation

SKM Pouch Pack-off · Line 4 & 5
7,200 pouches per hour per line.

A working model of the new pouch casepacking system for PT. Indolakto, laid out from the approved hall layout. Every pouch, case and pallet is its own object. On Line 4 the pouches run from the filler through a vane conveyor and an ABB IRB 390 delta robot into cases, then through the case sealer, checkweigher, printer, spiral and hanging conveyor to the existing ABB IRB 660, which palletizes Line 4 and Line 5 side by side. Each machine's capacity comes from its own motion.

Time speed

Random failures Machine labels

Fillers Line 4 Line 5

Property of
PT. Autoen Industri Teknologi

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Running (green light) Starved, waiting for input (amber) Blocked, downstream full (amber) Down (flashing red) Pallet change / magazine refill

Simulation time

00:00:00

real time

Line 4 efficiency

—

Line 5: —

Line 4 filler output

—

average of the last 5 minutes

Pouches packed L4

0 kg SKM

Cases sealed L4

12 × 545 g each

Pallets L4 · L5

56 cases per pallet

Machine panel

Change setpoints with − / + · actual speed = average of the last 60 seconds ·

Machine	Setpoint	Actual speed	IN	OUT	Status	Running

Selected machine

Pouch casepacker

Speed

MTBF (min)

MTTR (min)

Filler output per minute

━ Line 4 · ┅ Line 5 · last 60 minutes, in pouches per hour

How the model works

Layout follows the approved hall layout (column grid 5.0 / 7.0 / 6.0 m bays, 3.5 m clear height) and the pouch casepacker general arrangement drawing: 6.25 m infeed modular conveyor, speeder & reject belt, vane conveyor (1,750 × 330 mm), main frame 1,740 × 1,640 × 2,400 mm, box opener for 2 cases, gap maker, sealer, checkweigher, reject pusher and gravity roller.
Pouch: 545 g SKM pillow pouch, 175 × 105 × 32 mm (assumed). Case: 445 × 235 × 195 mm with 12 pouches in 2 shingled layers of 6, which matches the 6-cup heads and the 455 mm head spacing in the gripper drawing (assumed, replace with the real case spec).
Fillers run at 7,200 pouches/hour each (assumed rated speed). They are the critical machines; downstream machines have more capacity so buffers drain after a stop (V-curve): vane loading about 8,900 pph, erector 720 cph (8,640 pph), sealer 780 cph, palletizer about 1,650 cph for both lines.
The vane conveyor is servo-indexed: one pocket (62 mm) after each pouch and 145 mm between blocks. Its capacity comes from the index motion plus the 0.22 s it takes the speeder to throw a pouch into a pocket. The robot may pick a pair of blocks anywhere inside a 0.6 m window; if it falls behind, the vane stops and pouches back up on the infeed.
Pouches and cases travel on 1D accumulation conveyors along the real 3D path. Cases rest on the belt across their footprint, and their spacing grows in bends and at changes of slope so they never overlap (checked with a 3D box-collision test every 0.1 s over 30 minutes, with failures).

Delta robot: ABB IRB 390-15/1300 (15 kg, Ø 1,300 mm working range). Arm lengths are approximated (base radius 300 mm, upper arm 520 mm, lower arm 1,120 mm), with analytic inverse kinematics and straight-line moves at 2.5 m/s and 16 m/s². No official 3D model is embedded; the robot is drawn from basic geometry.
Palletizer: existing ABB IRB 660-180/3.15 (4 axes; J1–J3 130°/s, J6 300°/s) drawn with the official ABB Library model, on a 650 mm pedestal. Motion stops at every point (no zone blending), so cycle times are slightly conservative.
Line 5 keeps its existing pack-off, spiral and hanging conveyor, modelled in less detail. Pallet change takes 14 s; full pallets leave towards the ASRS conveyor.
Speeds, MTBF and MTTR are examples and can be replaced with vendor and plant data. About 0.2% of pouches are flagged by the filler and rejected on the speeder, and 0.08% of pouches slip off the gripper; the checkweigher catches the light cases.