Campetella – best Fakuma exhibition ever

18.11.2021

Speaking at the October 2021 Fakuma plastics industry fair in Friedrichshafen, Germany, Marco Marconi, Sales Area Manager at Campetella Robotic Center srl, an industrial robot producer and automation solutions provider headquartered in Montecassiano, Italy, said “it was the most successful ever Fakuma fair”. Despite the same number of high-quality contacts as at Fakuma 2018, visitors were mainly management-level decision makers.

Campetella's FAKUMA stand, October 2021. Source: Campetella

Visitors came from all of the most important German packaging players, while medical and automotive sectors were also represented. All of them used the opportunity to visit again a trade fair to renew and gain contacts and to become acquainted with the latest technologies, following Fakuma 2020 cancellation. The covid 19 pandemic, as stated by Marconi, sparked an explosive growth in medical and packaging industries whilst the automotive industry’s growth was prompted by the investments in electric cars. The global market is changing abruptly, and both large and small companies need to automate to stay competitive and gain advantages over their competitors.

“Campetella benefits even more from this growth, as it is outstanding at providing All-In-One standardized automation solutions”, Marconi explained, adding that staff shortages worsened by the pandemic encourage investment in Campetella’s automation solutions.  As a matter of fact, large companies cannot suffer from a labour shortage when it comes to repetitive tasks, struggling to find and keep operators to package finished products.

Marconi says Campetella solves this problem with a complete range of standard robots that can be integrated within downstream automation solutions. Rather than being limited to just side- or top-entry part and sprue removal from injection moulds, Campetella can perform all quality control and packing functions. Above all, Campetella’s Selective Compliance Articulated Robot Arm (SCARA) excel in packing, placing items directly in cardboard boxes, then passing them on for AGV (Automated Guided Vehicle) or AMR (Autonomous Mobile Robot) transfer to warehousing.

No better opportunity as Fakuma 2021 for Campetella, in partnership with Engel and Arburg, to show its fully automated IML stack moulding packaging solutions. Noteworthy, Campetella’s ultra-high-speed take-out GS2 Gunshot X-Series top-entry robot for packaging applications with cycle times down to as low as 2.3 seconds, was exhibited at its own stand. Last but not least, Campetella’s high performance and compact CX1 E-series robot was running at Matsui and JSW’s stand.

Marconi stresses, “Having all these robots managed via one common EVO control system makes life easier since the operators need to be trained only on one programming language. Furthermore, the shared robotic platform among all Campetella products optimizes the management of components, spare parts and enables efficient customer service. This is our strength, so is for our customers.

Campetella increasingly uses lightweight design. This ranges from carbon fibre, wherever possible, to additive manufacturing of hundreds of components overnight in a much cleaner and faster process than traditional CNC production. When 3D printed in PA12 (Polyamide 12), such parts are much lighter than metal equivalents, so enable robots to work faster and free of vibrations. Marconi points out the high degree of vertical integration: “We try to do anything that CNC can make, so we produce 80% of our components for robots ourselves”. Campetella is replacing pneumatic actuators where possible in favour of servo-electric drives using motors from Kollmorgen in the US, the worldwide leader for the production of servo-motors. By doing so, Campetella aims at reducing CO2 emissions while increasing reliability and efficiency.

Business status

Marconi says Campetella has 135 direct employees, plus access to and support from 105 staff working in 26 external sales/service and distribution companies. Campetella expected turnover of €21 million in 2021, with €38 million target for 2025.

A new 7,500 square metres production hall in 2022 will almost double floor space from today’s 8,500 square metres, to accommodate this business growth and enable robot installations to rise from 500/year to 1,200/year in the following years. Campetella have decided to establish subsidiaries in Germany and in the UK in 2022 and another one in the US in 2023. Not to forget the long-lasting strategic partnership with Sumitomo (SHI) Demag plastics machinery, which presented at Fakuma 2021 its first own-branded robot series solution, being the mechanics provided by Campetella

Campetella's FAKUMA team, October 2021. Source: Campetella

Pipe and hose extrusion

Campetella has a very long 35 years history in coiling machinery for 25-50 mm diameter extruded irrigation pipes and water hoses, an area which also now has shown worldwide explosive growth in all industrial countries, “so we will establish our own business unit for this“, Marconi revealed. The company’s SCARA robots additionally pack and stack these items. Although coiling machinery calls for different automation than with injection moulding, “the downstream automation is the same, with the same know-how, so it’s an example of allowing modular systems to be used for a number of different industries”, Marconi added.

Event preparations

The preparation for the next trade shows for the major plastics industry have already started, such as Fakuma, Plast/Milano, Plaspol, Interplas, NPE etc. and the forthcoming K 2022, where Campetella continues to exhibit “with a strong presence” in Hall  12, in the company’s 125th anniversary. This involves finding projects and working with renowned injection moulding (or extrusion) machinery producers on what is to be shown, companies calling Campetella their “first choice partner for innovative integrated post-moulding solutions.”

The latest CRC2020 Campetella Robotic Calling open house in Montecassiano also took a lot of organisation and effort in running it through the entire month of October 2020, with more than 400 visitors attending – which also had an impact on the excellent preparation and effect of Fakuma 2021.

Main Fakuma exhibits – more productivity in less space

Campetellla's FAKUMA exhibits, October 2021. Source: Campetellla

“This IML plant is one of a kind”, explains Reiner Schmid, ARBURG’s Senior Application Manager Packaging, “it is an extremely compact, fast, efficient and reliable packaging solution.” MODULA Twin Maxi – IML & stack moulding on an ARBURG IMM (stand A3 - 3101): Fully automated system for simultaneous IML production of containers and lids on a 2-level stack mold, that would normally require two separate IMMs, molds and automations. Maxi Twin is designed for IMM up to 12.000 kN.   Total cycle time at the fair:  5,5 s. Interlock time: 1,6 s. The two different parts are produced in a 4 + 4-cavity mould on a hybrid ALLROUNDER 1020 H “Packaging”. The carbon fibre arms reduce vibrations while guaranteeing excellent label positioning. The full-servo label feeder made of carbon fibre perfectly fits both the 5-sided and flat labels. The rotary table on the label magazine allows easy and safe label refilling while the robot is in operation. After checking each side of both containers and lids, a 7-camera system rejects only the non-compliant parts.  Just past the quality control system, the octagonal containers and lids are aligned and stacked (Scara X-Series SPIN 2) on the discharge belt face down to guarantee immaculate hygiene.

Campetella's high-speed IML-system MODULA MAXI TWIN, FAKUMA, October 2021. Source: Campetella

MODULA W – IML & stack moulding on an Engel IMM (stand A5-5204): Fully automated system for IML production of margarine tubs on a 2-level stack mold, designed to reduce footprint on the ground while maximizing productivity. Campetella robot: high-speed side entry robot for stack moulding, MODULA W, for IMM up to 4.500 kN. Total cycle time at the fair:  4,7 s. Interlock time:  1,2 s. The tubs are produced in a 4 + 4-cavity mould and stacked face down – with the Scara X-Series SPIN 2 – for immaculate hygiene. Minimal footprint: the vertical feeders for 5-sided labels are extremely compact to optimize the space available. No axis vibrating: the robot’s carbon fibre arms reduce vibrations while guaranteeing excellent label positioning. An in-line inspection system makes sure that the quality of stacked tubs is perfect.

Campetella's high-speed IML-system for bins and lids, FAKUMA, October 2021. Source:Campetella 

Campetella's high-speed IML-system for bins and lids, FAKUMA, October 2021. Source:Campetella 

For more information please visit www.campetella.com