A Guided Tour of RETAL PA: Creating High-Quality, Responsible Packaging.

Summary

This video offers a detailed virtual tour of Rittal's PA facility, guided by Matt Barker, the National Manager. It covers key areas like the visitor lobby, safety measures, PPE requirements, and various production areas. The tour highlights quality assurance processes, including machinery for testing caps, resin, and preforms. It showcases different production lines and equipment like injection molding machines, automated robots, and grinding systems for recycling plastic. Additionally, the video touches on Rittal's commitment to safety and quality through advanced monitoring systems, vision inspections, and environmentally conscious recycling processes.

Takeaways

• 👋 Welcome to the Rittal plant virtual tour led by Matt Barker, the National Manager.
• 🖥 Visitors must sign in using a touch screen kiosk, and the host will be notified via text or email.
• 📊 The Shot Scope monitoring system tracks real-time machine statuses, with color-coded indicators for operational status: green (running), red (down), and yellow (attention needed).
• 👔 The main office houses key staff, including the president, HR manager, supply chain manager, sales, finance, and planning teams.
• 👷‍♂️ Safety protocols include wearing PPE (toe covers, lab coats, beard nets, safety glasses) and no loose jewelry when entering the production area.
• 🔬 The quality assurance lab conducts tests on preforms and resin, using machines like the CMM, color spectrophotometer, and removal torque machine to ensure high-quality standards.
• 🏭 The plant’s PET production area uses 500 and 400 machines to produce parts, running multiple mold cavities and completing processes within seconds.
• 👁 The HDPE production area employs a vision system to ensure each piece meets quality standards before being packed.
• 🚂 Resin for production is delivered via rail cars and stored in silos, with each silo holding specific resin types.
• ♻ The plant uses a grinding system to recycle plastic scrap into reusable material, reducing waste and cutting costs.

Q & A

What is the primary purpose of the visitor kiosk in the lobby?

The visitor kiosk is used for visitors to sign in using a touch screen. Once they sign in and select their host, the host will receive a text message or email indicating that the visitor is on-site.

What information does the Shot Scope monitoring system provide?

The Shot Scope monitoring system tracks the real-time status of machines on the production floor. It shows whether machines are running (green), down (red), or need attention due to an issue (yellow).

What safety measures are required before entering the production floor?

Visitors must wear appropriate PPE, which includes toe covers to prevent foot injuries, lab coats, beard nets, safety glasses, and hair nets. They are also required to wash their hands, and no loose jewelry is allowed except for a wedding ring.

What is the purpose of the quality assurance lab?

The quality assurance lab tests preforms and caps for dimensional accuracy, clarity, color, gate thickness, and intrinsic viscosity. The lab also tests incoming resin samples to ensure they meet production standards.

What types of machines are used in PET production, and what is their function?

In PET production, they use 500 and 400 injection molding machines. These machines can run different products and molds with various cavity configurations (e.g., 76 or 96 cavities). Each cycle produces 96 parts approximately every 9.5 seconds.

What is the process for ensuring quality in HDPE production?

HDPE production involves a vision system that checks each piece for quality. The system ensures the parts are properly oriented, and any defects are detected before the parts move to final packaging.

How does the company apply ink to caps in the Desco top printing machine?

The Desco top printing machine loads four different colored inks that are applied to the caps using heat. The caps are then checked by a vision system before being packaged.

What is the purpose of the laser etching machine?

The laser etching machine is used to print under-the-cap codes for promotional purposes. The caps are loaded and oriented, and the codes are etched using a laser.

How does the company handle the resin unloading process from rail cars?

Rail cars deliver resin, which is sampled and tested for quality before being unloaded. The resin is then stored in one of six silos, with the capability to load two silos simultaneously depending on production needs.

What is the role of the offline IMD resource system?

The offline IMD resource system is used to inspect and sort suspended or quarantined totes from production. The system uses a vision system to detect defects like discoloration or contamination, and good parts are returned to the warehouse.

Outlines

00:00

🏢 Welcome to the Rittal PA Virtual Tour

In this introduction, Matt Barker, the national manager of Rittal, welcomes visitors to the virtual tour of their facility. The lobby has a visitor kiosk where guests sign in via a touchscreen, notifying the host upon arrival. The lobby also features a monitor displaying real-time machine statuses through the Shot Scope system, which shows if machines are running (green), down (red), or in need of attention (yellow). The nearby main office houses the president, HR manager, supply chain manager, and other key departments. The tour begins in the warehouse production area.

05:04

🦺 PPE Room and Safety Guidelines

Before entering the production area, the PPE room is introduced, emphasizing safety measures. Visitors are required to wear protective gear, such as toe covers to avoid injury from forklifts or overhead hazards. Handwashing is mandatory, and earplugs are available for those staying over eight hours. Visitors also wear lab coats to prevent contamination, alongside beard nets, hairnets, and safety glasses. No loose jewelry is allowed except for wedding rings. Once properly equipped, the tour proceeds to the production floor.

10:05

🔬 Quality Assurance Lab Overview

The tour enters the quality assurance lab, where preforms and caps are tested for quality. Heather, a quality technician, explains the machines used. These include the CMM for measuring cap dimensions, a color spectrophotometer for testing clarity and color, and tools for assessing gate thickness and height. Other equipment like the IV machine measures resin viscosity, and the GC tests AAA in resin and preforms. The removal torque machine tests cap tightness, ensuring high-quality products for customers.

🏭 PET Production Area and Process

In the PET production area, there are five IPAD 400 machines that run various products using different molds and hot runners. Each machine can produce 96 parts every 9.5 seconds. The process is explained in detail, from mold closing to injecting, filling, cooling, and transferring parts onto belts. Robots manage the parts, with a conveyor system loading totes, and an automated alert signals the end-of-line operator when the totes are full. The machines allow Rittal to produce large volumes of parts efficiently.

⚙️ HDPE Production and Vision System

In the HDPE production area, there are two Contes 300 ICAP 300 machines and one Ecole 420. Though no live demonstrations are available, the molding and filling process is similar to PET production. The key difference in HDPE production is the use of a vision system to inspect each part for quality. The system orients the pieces, checks for defects, and ensures that only high-quality parts are moved into boxes for palletization. This vision system ensures that any defects are identified and removed efficiently.

🖨 Cap Printing and Laser Etching

The tour moves to the cap printing and laser etching machines. The DESCO top-printing machine applies ink to caps using heat, and a vision system ensures the quality of the printed caps. The Tampo laser etching machine is used for specialized etching on caps, such as promotional codes under the cap, using precise atomized lasers. Both systems are essential for adding branding or promotional features to the caps while maintaining high quality.

🚂 Resin Delivery and Storage System

The resin supply system is highlighted, with rail cars delivering resin to the facility. Samples from the cars are tested in the lab to ensure quality before being unloaded into one of six silos, each holding a specific type of resin. The Goador loading system allows two silos to be loaded simultaneously based on production needs. This automated resin handling system ensures continuous and efficient production.

🔄 Resin Room and Blending Process

Inside the resin room, the dryers are loaded with material from the six silos. Five identical blenders combine resin in precise percentages based on customer requirements (e.g., 85% virgin resin, 10% rPET, and 5% regrind). This automated process minimizes manual intervention. Additionally, the bulk sack unloading system helps move resin into silos, while inline metal separators prevent contamination before materials reach the dryers.

🔍 IMD Quality Inspection and Defect Handling

In the IMD resource area, quarantined totes from production are inspected for quality before being sent to customers. The system can detect defects such as discoloration, contamination, or specific part issues, and it can reject parts based on cavity-specific defects. Rejected parts are sent to a separate belt for disposal, while good parts are placed back into the warehouse for sale. This rigorous inspection ensures only high-quality products are shipped.

♻️ Grinding System and Recycling Process

The final part of the tour shows the rapid grinding system, which recycles plastic scrap to reduce waste and costs. Totes of scrap are loaded into a dumper, fed through a conveyor, and ground into flake plastic by a rotary blade system. Metal detectors ensure no metal enters the grinding process. The ground material is then processed through a second metal separator and sorted into sacks for future use, helping minimize environmental impact while keeping production efficient.

Keywords

💡Shot Scope Monitoring System

The Shot Scope Monitoring System is a real-time tracking system used to monitor the status of machines and processes in the plant. It shows whether machines are running, down, or need attention based on color codes (green for running, red for stopped, yellow for caution). This system ensures efficient plant operations by providing instant updates, which is crucial for maintaining production flow.

💡PPE (Personal Protective Equipment)

PPE refers to the equipment required to ensure the safety of workers and visitors on the production floor. In the video, specific PPE like toe covers, lab coats, hearing protection, and safety glasses are mentioned as essential for protecting individuals from hazards such as falling objects, noise, or contaminants. This emphasizes the company's commitment to safety in the workplace.

💡CMM (Coordinate Measuring Machine)

The CMM is a device used to measure the dimensions of caps and preforms, ensuring precision and quality. In the video, it is located in the quality assurance lab and is part of the testing process to ensure products meet strict dimensional standards, which is crucial for maintaining high product quality.

💡IV (Intrinsic Viscosity)

Intrinsic Viscosity is a measure used to assess the quality of resin and preforms by testing their molecular weight. In the video, the IV machine in the quality lab tests this characteristic to ensure the materials used in production meet the necessary quality standards for forming strong, durable products.

💡HDPE (High-Density Polyethylene)

HDPE is a type of plastic used in the production of certain products within the plant. The video mentions HDPE production machines and the use of a vision system to ensure the quality of HDPE products. This material is widely used in packaging and other applications due to its strength and durability.

💡Tampo Laser Etching Machine

The Tampo Laser Etching Machine is used to print codes or promotional information under bottle caps. This machine adds value to the final product by allowing customization for different clients. The video describes its function as part of the overall production line, contributing to the flexibility of the plant’s output.

💡Rail Siding

Rail Siding refers to the area outside the plant where rail cars deliver resin used in production. The video explains that resin samples are taken from these rail cars for quality testing before being loaded into silos. This process is a key part of ensuring that the plant has a consistent supply of raw materials for manufacturing.

💡Vision System

The Vision System is a quality control mechanism used in HDPE production to inspect each piece for defects like discoloration or contamination. The video highlights how this system ensures that only high-quality products are sent to customers, rejecting defective items before they reach the packaging stage.

💡Grinding System

The Grinding System is used to process scrap plastic into reusable material, helping reduce waste and lower production costs. In the video, this system grinds defective or leftover preforms into plastic flakes, which are then reused in future production runs. This contributes to the plant’s environmental sustainability and resource efficiency.

💡Bulk Sack Unloading System

The Bulk Sack Unloading System is a part of the resin handling process, where large sacks of plastic material are emptied into silos for later use in production. This system plays a crucial role in the automated handling of raw materials, ensuring that the plant has a steady and efficient flow of resin for its production needs.

Highlights

Welcome to the Rittal PA virtual tour led by Matt Barker, National Manager at Rittal.

Visitors sign in using a touch screen kiosk, and the host is notified via text or email.

Real-time monitoring of machine statuses through Shot Scope system; green means running, red means down, yellow signals a need for attention.

Introduction to the PPE room with safety measures, including mandatory toe covers, hand washing, lab coats, safety glasses, and specific clothing restrictions.

Quality Assurance lab tests resin samples and products, using advanced machines like the CMM and spectrophotometer.

The PET production area includes 500 and 400 machines, capable of producing 96 parts every 9.5 seconds.

Automated production flow with robots and conveyors handling the movement and sorting of products.

The HDPE production section features a live vision system for quality inspection.

Desco top printing machine applies inks onto caps through a heat process, followed by laser etching for promotion codes under the caps.

Rail cars deliver resin at night, which is unloaded into one of the six silos after quality testing.

In the resin room, material is blended from silos to match customer requirements, using a self-automated process.

Offline IMD resource room checks quality of quarantined totes, using vision systems to detect specific defects like discoloration or black specks.

Rittal's commitment to environmental sustainability is highlighted by the rapid grinding system that recycles plastic scrap, reducing landfill waste.

A metal detector in the grinding system ensures that no metal contaminates the material being reused.

Ground plastic scrap is converted back into usable material, significantly reducing resin costs and enhancing sustainability efforts.

Transcripts

hello and welcome to our tall pa my name

is matt barker national manager here at

rittal and welcome to our virtual tour

follow me inside right now and we'll get

you started

welcome to the lobby rotol to the left

of me is our visitors kiosk uh we asked

all of our visitors to come in and sign

in using the touch screen

while accessing the touch screen you

look for your host name and once

complete they will get a text message or

an email show that you're on site

while you're waiting we please ask you

to have a seat and your host will be up

here for your conference call meeting or

tour of our plant

above our seating area is one of our

monitors this is showing our shot scope

monitoring system

we use shot scope to keep track of all

of our process and machines in real time

shows our machine statuses if it's

running or or down obviously green means

go that we're running red means we're

down and yellow would mean that we need

to pay attention to something because

something's not running quite up apart

to the left is our main office in our

main office we have our president and

ceo we have our hr manager we have our

supply chain manager and we have our

sales finance and planning teams

and over here to the right as we're

about to take you is the door to our

warehouse production where we will begin

our tour of retal pa

so we are now in the ppe room before

entering production uh ever told we take

certain safety measures to protect you

and to protect our customers so certain

ppe must be worn while the production

floor right here we have a pt guideline

to show what

what measures we take

below right here our

toe covers this way we can make sure you

don't get your foot crushed by forklift

traffic or something that could possibly

fall from overhead

as i start moving to my right

we require all visitors to wash our

hands before under production

we have hearing protection available if

you want to wear it we only require

people to wear earplugs if they're here

more than eight hours

also to my right is our lab coats we

require all visitors to wear

lab coats this way protects our

customers from possibly having

contaminants from dog hair or cat hair

on your clothes

we also have beard nets

safety glasses and hair deaths that we

require wearing production also no loose

stroller we can be worn

from below from the waist up so no

watches no earrings no necklaces the

only you can wear is a wedding ring if

you're wearing one and over here is our

door production where we can take you on

the floor and start to show you what we

have have to offer we're told va

so now we're about to enter our quality

assurance inside of the lab we test our

pre-forking caps right from the machines

we do some dimension tests and so forth

uh we also test incoming resin samples

to make sure we use production but we

can also test uh sample products see if

we can make products uh requested by our

customers

inside of introduce you to heather

she's one of our quality technicians and

she is going to explain to some what

some of the machines down here do

this is the cmm that we use to test the

dimensions of the caps

and preforms

this is the color spectrophotometer that

we use

which tests for the clarity in the clear

preforms and test the color in the

colored ones

and over here are different gadgets that

we have to test the gate thickness and

the height

over here we have the iv which tests the

intrinsic viscosity of the resin and the

preforms

and this is the gc

which we test

the aaa in the resin and the free forms

and here's the

removal torque machine

and the caps are in here we test the

removal torques of our caps

[Music]

in here test for our secure seal testing

make sure the caps

are on tight

this is the capper so we can cap it to

test our caps

and these are some of the routine things

we run on a day-to-day basis to make

sure our product is of the highest

quality for our customers

this is our pet production area in pvp

production we have 500

ipad 400 machines

um each of them can run different

products we have different hot rotors in

different modes

we can run 76 cavities 96 cavities

and other ones depending on your needs

we'll give you a quick overview of our

t1 line real quick

so right now the mold closed we're

filling the multiple plastic

transfers at our hmi it's showing the

actual process live through what the

machine's seeing

right now we're injecting and filling

folding

we're going to poland now we're holding

open transfer happens and we're putting

96 pieces on the ground

on the belt we're doing this every nine

and a half seconds approximately so we

make a lot of pieces pretty fast down

here from there when the one opens it

goes to the robot

the robot holds four stages of parts

where we continue pulling for the

product

from there the full pick picks the parts

off the pulling plate puts it on the

belt

the belt start transferring each other

from there the belts load our toes

and once our toes are full we'll get a

blue light

telling the end-of-line

operator so blue won't move the boss off

put a new one on and we do this over and

over again all day because again all

five machines are identical and we can

run different various uh full and hot

runners to uh make products

so over here hdpe uh production uh

section or warehouse

in atp we have two uh contest 300 icap

300 and we have one equal 420

uh unfortunately right now we're not

running so i can't show you a live

demonstration but inside here's the mold

pretty much the same as uh

i mentioned before we're still

filling the bowl with my plastic

it goes into a conveyor the container

loads the bunker now here's where it

gets a little bit different with uh hdp

we have a live um vision system where

we're checking each piece for quality

it goes through gets oriented

goes through the vision system

on the back

of the conveyor and into the boxes

for uh palletization at the end

this is our desco top printing uh

printing machine uh we can load four

different colored inks uh we go the inks

are identified to cliches that are

applied to the caps

caps go through here and used by heat

we're able to apply the ink to the cap

and then

revision system and into boxes

to my left is our tampo laser etching

machine what we do is we load the caps

in the bunker

gets oriented

put through the uh laboratory using uh

atom that we put in the cap production

we can get it under the under the cap

code for certain promote promotions done

by some of our customers

so now we're outside this is our rail

siding uh to my left is uh our rail cars

rail cars come in at night they're

carrying our resin

we sample them take the samples to the

lab they'll uh check it make sure it's

good quality we get the okay to unload

it

we have six silos we can load each silo

we hold a specific resin and we load it

over and over again and we're using our

goals our door loading system so we have

the capabilities to load two silos at

one time depending what we need for the

day

this is our resin room in our resin room

what we do is where we load our dryers

in line there is five uh five identical

uh blenders

we're pull material from our six silos

outside through the hub you can see to

the right looks like an octopus uh we

set our fixed percentages based on our

customer's needs so we could run 85

virgin 10 rpent 5 uh regrind from mid

house

and we feed our drivers and pretty much

maintained just through a little bit of

monitoring but we pretty much

self-automated

over to my right right now is our bulk

stack unloading system and we take a

whole sack lock we'll hang them and uh

suck it outside and load our silos and

we'll explain about the silos here in a

second

these are inline metal separating

systems each machine has one and it

guarantees that we're separating metal

before it gets to the dryer and before

it gets to your product

hi again this is our offline imd

resource uh we use this restore to take

suspended and quarantined totes from

production and bring up here for another

set of eyes for quality before we send

out to our customers

we'll take these pendant totes and dump

them in the dumper

the dumper goes to the bunker the bunker

then feeds conveyor belt conveyor system

the conveyor system feeds the orienter

the orient will start oriented parts

that feed the vision system

our vision system then has the

capabilities to pick up certain defects

based on the programming performed by

our quality quality supervisor engineer

some of the defects we look for are

discolored parts

long gates contamination black specks

and we can even go cavity specific so

for example we can reject every number

six from the coast uh that we feed the

system with

the rejected parts then go to another

belt system and the good parts also go

to that belt system where the rejected

parts feed it to the middle that we end

up being positive strap and the left and

right

are good parts that we put back in our

warehouse for sales

this is our rapid grinding system here

we take our plus scrap and grind for

future use

this also saves on resin costs and it

also saves the environment this way

we're not putting all the plastic scrap

to landfill so here we take our positive

scrap

we take the toast put them in the dumper

the dumper then feeds

the bunker

the bunker starts feeding the belt

system the conveying system that feeds

the grinder once going up the conveyor

we have a metal detector and if we sense

any amount of metal the belt will stop

so the operator can then inspect to see

if there's anything that could possibly

damage the blades but most importantly

make sure there's nothing in the

material that we'll put back into our

machines could possibly end up in uh

good preforms again

this is the blade system itself the

grinding system inside are rotary blades

that take the preforms and grind and

tread them down to flake plastic

from there it's fed through the

conveying system

back down through a second metal

separator to make sure we have no metal

sacs the offspec goes to the right the

good material will then feed the sac and

then we'll take this sack and put it

back in the warehouse for future use

here is an example of what the grinding

preforms then become before use