Breckle is one of the largest mattress manufacturers in Germany. However, demand has been limited since the beginning of 2020. At the same time, the healthcare industry reported a high demand for respiratory masks in February 2020, which is why the company decided to switch part of its production to respiratory masks.
The company trade show faced several challenges at the same time: Time and cost pressure, as well as the increasing need for automation as demand grew. With Low Cost Automation, a modular automation solution was developed for packaging the masks - cost-effective, delivered quickly and suitable for entry-level automation. Thanks to the modular Low Cost Automationsystem, the solution can be easily and quickly expanded to meet individual requirements. Today, Breckle produces around one million masks per week.
The problem
In order to be able to react as quickly as possible to the unforeseen demand for respiratory masks, Breckle GmbH had to restructure its own production in a hurry. Initially, the masks were elaborately manufactured by hand. As demand increased, the company acquired the expertise and gradually automated mask production. In addition to the fast delivery and low costs of the automation solution, the focus is on the use of hygienic components for the production and packaging of respiratory masks. In addition, the available space in the production hall is limited, which is why the machines need to be as space-saving as possible. To ensure that the respiratory masks can be certified as a German brand, the material for production is not purchased in China. In order to be able to keep up with the cost and hygiene standards of foreign manufacturers, Breckle relies on components from Low Cost Automation, among others, for its highly automated production and packaging.
The solution
Every week, four machines with around 20 employees produce around 100,000 surgical and FFP2 masks. Two fully automatic packaging systems based on the igus® gantry system are used for the manual and monotonous packaging of the masks. The masks, which have successfully passed the automatic quality control, are filled into the cardboard boxes via a conveyor belt using drylin® bearings and shafts, which are automatically provided by the gantry system.
Driven by a flat toothed belt drive, the drylin® gantries move absolutely lubrication-free and therefore fulfil high hygiene standards. For the entire robot kinematics, plant manufacturer Ximaj uses a B&R control system, which in turn communicates with a D1 dryve-control system from igus® to control the system's motors. With the introduction of the quality assurance system and the automatic packaging machines, mask production was reduced from three shifts to two. In addition to the time savings, there is also a significant cost advantage. Automation solutions from LCA usually pay for themselves within a year. In addition, the tribologically optimised components are lubrication and maintenance-free. With increasing demand for respiratory masks, Breckle will continue to expand its automated production in the future.
