Sprick Insights: Reliable, automated, sustainable
Hörmann is optimising its packaging operations with the PaperJet®, the PaperJet® Winder and a robot-based cushioning solution from Papier Sprick
In the packaging and dispatch process, one thing matters above all else: a reliable, seamless workflow, even when dealing with high volumes and changing requirements. Hörmann KG Antriebstechnik in Steinhagen is a forward-looking development and production site. The company develops and manufactures complex garage and entrance gate operators, as well as industrial drive solutions, for which reliable packaging is a crucial step in the process chain. Every day, around 1,500 packages are prepared here for worldwide dispatch, ranging from the smallest cardboard box to full pallets of rails and operators.
For Hörmann, this was precisely where the challenge lay: the setup previously used for preparing the cardboard boxes – from automatic erecting to filling with cushioning material – was not reliable. This led to repeated malfunctions, necessitating manual intervention and leaving this stage of the process vulnerable. “The previous solution was very error-prone, meaning that almost half a working day was needed to rectify faults. We were looking for a solution that didn’t require a great deal of staff input and didn’t involve employees having to do much manual work,” says Thore Hilgenhöner, Team Leader for Order Picking at Hörmann.
This area was reorganised following the implementation of a paper-based, automated solution from Papier Sprick. The focus was on increasing process reliability, utilising staff resources more efficiently and, at the same time, significantly improving material usage and sustainability.
In this interview, Thore Hilgenhöner, Team Leader for Order Picking at Hörmann, talks about how automation has helped to improve process reliability.
Process reliability through automation and standardisation
The aim of the automation was to utilise available staff resources more efficiently and to minimise the need for manual intervention. The new solution ensures a stable process, from the carton erector right through to the reliable insertion of paper padding to protect the goods in transit. “Thanks to the automated solution, our staff no longer need to stand by the machine but can let the system do the work for them. This enables us to increase output and make better use of our existing staff to cope with the sharp rise in volumes in the packaging department,” explained Thore Hilgenhöner, Team Leader for Order Picking at Hörmann.
The site now operates entirely on a paper-based system. Using the PaperJet® and the PaperJet® Winder, paper padding and paper coils are pre-manufactured centrally for all standard packing stations and made available as required. In addition, a fully automated, robot-based paper cushioning solution is fully integrated into the conveyor system and the overall process. This system uses two robots to fill the cardboard boxes – which have been automatically erected beforehand – with the required number of paper cushions, before the boxes are fed via the conveyor system to the respective packing stations.
Thanks to this combination of high-performance PaperJet® cushioning systems and integrated robotics, the supply of cushioning material has become significantly more reliable – with the result that this previously fault-prone stage now runs reliably without the need for manual intervention, and packaging processes have become more predictable.
In addition, material usage has been optimised: packaging tests carried out by Papier Sprick showed that the previous solution was, in some cases, oversized. With the precisely fitting cushioning insert, material consumption and handling can now be better controlled without compromising on product protection.
Availability and service: Direct, prompt, reliable
For Hörmann, the long-term functionality of this sensitive area is essential. That is why direct communication, prompt availability and a reliable supply of consumables are key factors in our partnership. Papier Sprick delivers exactly that: as a manufacturer of systems and 100% recycled paper ‘made in Germany’, it ensures both ongoing operational support and a reliable supply of materials.
In this collaboration, this is particularly evident through the direct contact and ongoing dialogue with Sprick’s sales team. Short lines of communication and rapid coordination make it possible to maintain a stable process. Furthermore, solutions such as the robot-based cushioning system are developed through close dialogue between Hörmann and Papier Sprick’s in-house mechanical engineering department. As a result, the fully automated paper cushioning solution could be seamlessly integrated into the existing plant and supports the aim of ensuring the packaging is set up reliably and consistently.
“The collaboration is thoroughly positive. Whenever we’ve had problems, someone has been there for us straight away – and we get everything from a single source, whether it’s machinery or paper.”
Sustainability and availability: paper instead of plastic
Sustainability is a key priority for Hörmann and is becoming an increasingly central focus in the company’s packaging too. Hörmann Antriebstechnik is working intensively on the sustainable design of its packaging: wherever possible, the use of films and plastics is avoided, whilst existing processes are continuously optimised.
Another important aspect here is how it is perceived by the end customer: paper-based transport protection made from recycled paper makes the commitment to sustainability visible, even at the moment of ‘unboxing’. The use of recycled paper certified by the Blue Angel, amongst other schemes, further reinforces this effect and consistently supports our sustainable positioning. Thore Hilgenhöner sums it up as follows: “We have been looking for solutions to move away from plastics and towards recycled paper for quite some time. Recycled paper with the Blue Angel certification fits perfectly with the direction we want to take together with Papier Sprick.”
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The transport system routes the drive units to the packing station.
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Shipping cartons are positioned and filled
with paper cushions fully automatically using the robotic system. -
The cardboard boxes are transported to the packing area.
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The drive unit and the cardboard box reach the packing station.
The employee simply has to place the product inside the box. -
The fully packaged component is secured inside the box ready for dispatch.
Result: A stable packaging process using less material and offering greater predictability
With the PaperJet®, PaperJet® Winder and the robot-based padding solution, Hörmann has established a setup that combines the key objectives:
- Greater process reliability through automation and more robust workflows
- More efficient use of staff, as manual intervention is significantly reduced
- Optimised use of materials through more precisely fitted cushioning instead of oversizing
- Reliable collaboration thanks to direct communication, local service provision and guaranteed material availability
- Greater sustainability through consistent use of paper-based transport protection and certified recycled paper
Find out right away how you can optimise your dispatch and packing processes:
We’ll package your product
Please send your product to the following address and we will return it to you safely using our packaging solution:
Sprick GmbH & Co.
Test Packaging
Hanfstraße 23
33607 Bielefeld
Germany
Please remember to provide us with a contact person and include a return address with the parcel. Alternatively, you can fill in this PDF and include it with the parcel.
Non-binding live presentation
Find out about the features of our systems in a personalised online presentation and ask any questions you may have. Simply request an appointment and we’ll get in touch with you!
What you can take away from this
Which Papier Sprick solution does Hörmann use for its packaging?
Hörmann relies on the PaperJet®, the PaperJet® Winder and a robot-based cushioning solution from Papier Sprick. This enables paper cushioning and paper coins to be pre-produced centrally for the packing stations and automatically placed into the cartons.
Why did Hörmann choose an automated packaging solution?
The solution previously in use was prone to errors and required frequent manual intervention, sometimes taking up to half a working day to resolve issues. The aim was to achieve reliable, process-secure automation that would ease the workload on staff and reliably cope with the increasing output in the packaging department.
What are the advantages of paper-based cushioning over plastic?
Paper-based cushioning solutions reduce the use of plastic in shipping, are more easily recyclable and can be produced on site as and when required. This reduces both material consumption and storage requirements.
How does Papier Sprick support customers such as Hörmann in their day-to-day operations?
Papier Sprick offers direct and prompt service and accessibility – from machine integration to ongoing support – and provides packaging solutions, machinery and materials all from a single source.
What results was Hörmann able to achieve with the new solution?
Hörmann has now achieved a stable, reliable packaging process with fewer manual interventions, reduced material usage and greater predictability, even with increased dispatch volumes.
