Insulation block wrapping machine
How do you package a product that breaks at the slightest pressure?
The Customer
Microtherm in Sint-Niklaas is a world leader in high-performance thermal insulation. Their products are used in the most demanding environments: from aircraft black boxes to insulation systems that must withstand temperatures of up to 1200°C. The company is part of the Etex group and combines automated production with manual assembly for both customised and standard products.
The Challenge
Microtherm produced porous, refractory insulation blocks that had to be wrapped in aluminium foil with glue. Until then, this was done entirely by hand.
This was time-consuming, labour-intensive, and brought too much variation in the end result. The question seemed simple: automate this process. The reality was different. A packing machine for this particular product did not exist.
Why this is not a standard machine:
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The product is brittle: One wrong move and the block breaks.
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Unpredictable aluminium foil: It folds differently from paper, springs back, and responds to temperature and humidity.
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Conflicting glue requirements: Fast enough to meet the takt time, but not so fast that the process pollutes.
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Wrapping "like a gift": The film had to close tightly and neatly around the product without damaging it.
Project Gallery
SMO's Solution
SMO developed a robot-controlled packing machine in which everything comes together. A robot picks up the fragile block without applying pressure. The block is positioned on a pre-glued aluminium sheet, the film is folded and closed around the product, after which the finished package goes to a discharge roller conveyor.
Glue under control
Proper adhesive selection and tight parameter control ensured that the process ran smoothly. No drying time problems, no contamination, no downtime.
Air instead of power
To shape the aluminium foil predictably without touching the product, SMO used aerodynamic effects. By targeted blowing, the foil closes neatly around the block without mechanical contact.
Engineering and production under one roof
During construction, it was found that aluminium foil is sometimes slightly pre-folded due to the way it is delivered in rolls. This completely changes its behaviour. Because engineering and production are side by side at SMO, the team was able to make adjustments on the spot. No waiting weeks for an external supplier. Adjust, test, move on.
The machine in action
The Result
The machine achieves the target speed and delivers the desired quality. Fewer personnel are needed, output is more consistent and the machine offers adjustable recipes for different product variants.
Throughout the project, I had a good feeling. This complex project came to a good conclusion.
Technical Specifications
- Type Robot-controlled wrapping machine (aluminium foil + glue)
- Product Brittle, porous refractory insulation blocks
- Key technology Glue control and air conduction for film forming
- Flexibility Adjustable recipes for quick changeover
- Completion 2022