Seven central robot cells were replaced at the global packaging manufacturer Gerresheimer, marking a resounding success despite various challenges. This project clearly illustrates why retrofitting is often highly worthwhile.
If you're looking for an expert in packaging and innovative solutions for the pharma, biotech, and cosmetics industries, Gerresheimer AG is the right place. Gerresheimer is not only a pioneer in glass packaging solutions but also in robot-assisted automation solutions. At their site in Essen, founded in 1723, ABB has brought seven robot systems up to the latest standard through an extensive retrofit, ensuring spare parts availability for the coming decade. Even adverse conditions, such as pandemic-related supply chain issues, did not affect the project's success and customer satisfaction. The key to this was proactive and solution-oriented communication.
High Operating Performance of Existing Equipment
At Gerresheimer in Essen, the furnaces never stop. Hundreds of thousands of glass bottles and jars, in both clear and brown glass, are produced daily.
“Our glass melting runs seven days a week, twenty-four hours a day without interruption.” – Ilyas Durmaz, Project Manager Cold End at Gerresheimer
Glass bottles are produced in high quantities per article, often resulting in massive amounts simultaneously moving along the cooling conveyors. This is where robotics comes into play: Reliable, precise, and with the necessary care, ABB robots place up to several hundred bottles per minute onto the workpiece carriers. After inspection, they are packed into trays by other ABB robots and palletized by a large ABB robot.
Except for palletizing with the industrial robot IRB 6700, the MultiMove solution from ABB is used in other operations. It allows the operation of up to four robots via one controller with a compact drive module for each additional robot. The robots' movements can be coordinated or executed independently.
Uncomplicated Exchange Without Significant Adjustments
Since more modern and powerful models were available, ABB's System Service experts were called in.
“We advise customers when they want to modernize a plant or optimize plant availability. That's why we proactively informed Gerresheimer that the currently used MultiMove solution could still be reordered and recommended an exchange. The advantages are clear: The customer receives a completely new system, consisting of robots and control, and is up to date with the latest technology for many years. At the same time, the effort for implementation and commissioning is limited, as only the hardware needs to be replaced without changing the design or any other interfaces.” – Frank Bildesheim-Glaubauf, Senior Project Manager at ABB Robotics System Service.
Photo: Gerresheimer AG 
Photo: Gerresheimer AG
These compelling arguments convinced Gerresheimer to invest in the exchange of the two MultiMove robot cells – one with two and one with four robots – and the large robot IRB 6700 exchange. After a thorough analysis, a pre-installation with the new robot systems, including controls, occurred at ABB Robotics’ site in Friedberg, Germany. Since the latest IRC5 control generation was also used during the retrofit, customer programs had to be converted to the current version of ABB’s control software.
“We usually conduct a pre-installation for all brownfield projects we oversee. We thoroughly test both hardware and software and prepare the programming accordingly. This significantly reduces the time required for on-site implementation,” continues Frank Bildesheim-Glaubauf.
Quick and Proactive Communication During Delays
What initially seemed simple in theory brought unexpected complexity in terms of coordination and communication in practice. Due to the pandemic and the global semiconductor shortage, deliveries were delayed, and the systems could not be implemented immediately. This required close coordination and transparent communication. Additionally, machine utilization at Gerresheimer was very high. To minimize production downtime, it was essential to use the short windows when the equipment was not in production.
“We usually only had a few days for implementation,” recalls David Winter, Project Manager at ABB Robotics System Service.
Although the project did not remain within the original timeline, this did not diminish Gerresheimer’s satisfaction.
“ABB’s support was simply top-notch. We were promptly informed of any changes in the project timeline and could reschedule our production. Moreover, ABB experts always act solution-oriented. For instance, when the handheld devices didn’t arrive on time, ABB provided us with replacement devices. Additionally, each robot cell's implementation was 50 percent faster than initially targeted. All in all, simply an excellent all-around service.” – Ilyas Durmaz, Project Manager at Gerresheimer
ABB typically offers customers "Start-of-Production" support followed by production accompaniment after completing implementation work. Gerresheimer also utilized this service. An ABB technician was on-site during the initial period to respond if needed. Meanwhile, production is back in full swing.
