Grespania Automates Its End-of-Line for Ceramic Picking with Innova’s Stretch Hood
How can such a complex packaging process as ceramic picking be automated? Many distribution centers and ceramic manufacturers serving picking orders face the challenge of improving and automating their packaging processes. In the case of Grespania, one of the leading groups in the Spanish ceramic sector, the company relied on Innova’s packaging technology to address this challenge.
Innova proposed a Stretch Hood system specially designed for picking, capable of wrapping anything from a pallet with just one ceramic box to fully complete loads. The Stretch Hood system thus fills an existing gap in the automation of these types of loads, as neither automatic wrappers nor shrink-wrap systems can offer such versatility and total protection of the goods.
The new automatic packaging line for picking loads was installed at Grespania’s factory in Nules (in the Spanish ceramic Hub), the group’s factory and distribution center for ceramic products for large retailers throughout Spain. This installation adds to other projects Grespania has undertaken with Innova, such as a double packaging line at their facilities in the main factory in Castelló and a specialized line for XL formats and ceramic slabs in Moncofar.
Grespania’s Challenge: Automation for Picking
Grespania faced the challenge of improving its packaging for picking loads and automating a process that was previously done manually. At the time, loads were packaged using a manually applied shrink wrap system, so the proposed Stretch Hood solution improved both productivity and ergonomics in the workplace.
Another important factor to consider in picking lines is the variability in load sizes. Grespania’s plant serves as a distribution center for a wide range of clients, from small stores to large retailers. This means that some loads contain only a few ceramic boxes, while others are complete pallets.
2. The Solution: Stretch Hood Adapted for Picking
Innova Group presented an effective solution for all types of pallets: the Stretch Hood system, designed to adapt to the diversity of sizes and volumes in picking loads. The key to its success lies in its ability to efficiently wrap everything from the smallest loads to complete pallets, ensuring optimal protection in all cases.
The Stretch hood packaging line for picking loads at Grespania includes:
- Stretch Hood system for picking: The Stretch Hood Pro1 – S2 system includes a height measurement system with a laser, ensuring the wrapping fits the pallet’s exact size. Additionally, it has two Stretch Hood film reels to accommodate different pallet sizes, ranging from standard sizes like euro pallets or American pallets to special sizes of 800 x 500 mm or 1300 x 1300 mm.
The Stretch Hood wrapping not only provides Grespania with this versatility in packaging but also improves the product presentation thanks to the fully transparent film, which allows complete visibility of the contents while also improving logistics traceability for shipments to different distribution centers. Furthermore, the system provides hermetic protection against dust and external agents, a significant advantage in the transport and logistics storage of these loads.
- Conveyor line: The installation at Grespania included a pallet conveying line adapted to different pallet formats for both heavy and light loads. The conveyor line includes:
- Entry line for pallets, adapted to Grespania’s loading vehicles. The pallet entry was positioned next to the current picking station to facilitate future connection with this line.
- Pallet centering system before Stretch Hood wrapping.
- Special chain conveyor in the Stretch Hood system. This conveyor system combines chains and rollers for better pallet traction and wrapping of smaller loads.
- Pallet exit line with a turning system to adapt to the factory’s layout and allow for a spacious and efficient pallet accumulation and collection line.
3. Results for Grespania and Future Plans
The automation with Stretch Hood has allowed Grespania to increase its productivity by eliminating the manual process, reducing packaging time, and improving safety. The quality of the packaging has significantly improved, with loads uniformly protected regardless of their size or weight.
The use of Stretch Hood technology has also enabled them to reduce energy and plastic consumption compared to the manual system, contributing to the company’s sustainability goals. Moreover, the future integration of the new packaging line with other picking stations will ensure greater production flow, further optimizing the distribution process.
With this project, Grespania once again becomes a pioneer in automating a complex ceramic packaging process. Having already trusted Innova for the installation of Stretch Hood XL for its large formats—also an innovation in automation—they have done so again with this Stretch Hood solution for picking.
Grespania has expressed their satisfaction with the execution of the project:
Máximo Dolz, Technical Director of Grespania, commented: “It has been a pleasure to work with Innova Group again. We are very satisfied with the installation and the project’s results. We were already aware of the benefits of Stretch Hood and, the adaptability of this system has been key to solving this packaging challenge.”
Fernando Ferrer, Logistics Director of Grespania, added: “This installation has allowed us not only to improve efficiency in our picking process but also to enhance our brand image to the customer, whether in small orders or full loads.”
On behalf of Innova Group, Sergio Llidó, General Manager, stated: “This project has been a true example of how our solutions can be integrated and adapted to each client’s specific needs. We are proud to contribute to the innovation of a pioneering company like Grespania, with whom we hope to continue collaborating in the future.”
