Increase productivity and process reliability

Gierecker & Brökelmann, a Rheda-Wiedenbrück-based specialist in custom machine engineering, has developed a handling solution for a leading carpet manufacturer that significantly improves the efficiency and reliability of the production process for self-adhesive carpet tiles. The core of the system is a custom-modified needle gripper from Fipa.

The challenge:

In the production of carpet tiles, rectangular (1,000 × 250 mm) or square (500 × 500 mm) carpet tiles are die-cut from a carpet strand. Each die-cutting stroke produces eight carpet tiles. However, the self-adhesive backing on the underside of the carpet tiles, which serves as a subsequent fixing aid, makes peeling them from the die-cutting machine difficult. Previous gripper solutions quickly reached their limits here, as the necessary tear-off force could not be guaranteed.

The solution:

The system utilizes a modified version of the FIPA GR04.725 needle gripper. This standard needle gripper has 32 needles. In close consultation with the customer, the number of needles per gripper was reduced. Fewer needles per unit allow for greater penetration force into the approximately 7 mm thick carpet backing. This ensures that the needles reliably penetrate the stiff felt backing, remove the carpet tiles from the belt safely and without damage, and then easily detach from the pile.

The result:

The solution was a complete success: Every 7.5 seconds, eight carpet tiles are automatically gripped, separated, and stacked in the defined packing pattern. Processing both tile sizes with the same system increases flexibility and reduces changeover times. At the same time, process reliability was significantly improved, as the carpet tiles are gripped, separated, and stacked precisely without damage.

The advantages:

• Process reliability: Consistently high quality in every cycle
• Productivity: One carpet tile is processed every second
• Flexibility: Both square and rectangular carpet tiles can be processed with the same handling device
• Sustainability: Replaceable needle plates extend the service life and reduce material consumption

"With the customized needle gripper, we not only increased the customer's productivity but also raised process reliability to a new level," explains Hubert Rüschenbeck, Managing Director at Gierecker & Brökelmann. "The solution impressed the customer so much that another system is already scheduled for conversion." The idea for the customized gripper solution arose in close collaboration with Fipas field service team, who addressed the specific challenges and significantly advanced the project with their practical experience. The project demonstrates how customized solutions can optimize production processes and set new standards in efficiency and quality.