Smart automation for complex packaging processes at Rockfon

Rockfon, part of the ROCKWOOL Group, produces fire-safe and acoustic ceiling systems. To further optimise its production process, the company set out to automate the entire packaging workflow — from profile production through to palletising.

The main challenge lay in the complexity of the handling. Tasks that are simple for an operator, such as accurately placing aluminium T-profiles into boxes, are far more difficult to replicate with machines. Addressing these challenges was essential to improve efficiency and scalability.

ACE development & engineering delivered a fully automated packaging line capable of performing these complex operations reliably and consistently. The result is a seamless end-to-end process, with increased productivity and improved working conditions.

From manual work to a fully automated packaging line

Where the packaging process was previously largely manual, it is now fully automated using smart machinery and robotics.

ACE was responsible for the complete development and realisation of the installation, including:

  • concept development in close collaboration with Rockfon
  • mechanical and electrical engineering
  • PLC programming (Siemens S7-1500 platform)
  • machine build and commissioning
  • testing and optimisation

After packaging, the boxes are automatically palletised by a robotic system, creating a fully integrated process.

ace development & engineering ontwerp tot realisatie

van ontwerp tot realisatie

ACE development en engineering Rockfon oplevering inpaklijn

laatste check voor oplevering

ace development en engineering Rockfon tevreden team

tevreden ACE team

“Siemens components were selected throughout the entire installation. The SIMATIC S7-1500 platform serves as the PLC, working seamlessly with the decentralised ET200SP and ET200AL I/O systems. The low-voltage equipment, servo motors with drives and network switches are also fully based on Siemens technology.”

Koen Aerts - Project Leader Automation, ACE development & engineering Lummen

High performance and improved ergonomics

Shortly after commissioning, the installation was already running at 90% of its target capacity. However, the impact goes beyond performance alone.

The new packaging line provides:

  • significantly improved ergonomics for operators
  • reduced manual handling and physical strain
  • fewer errors and less downtime
  • more efficient operation through intuitive controls

Operators have been trained to work as specialists on the new line, with better oversight and less time lost due to false alarms or system interruptions.

Scalable and future-ready

The success of this project has led to further expansion. Rockfon has already invested in additional production lines for high-volume applications under T-profiles. These lines are running at full speed using Siemens technology and are ready for future scaling.

In één oogopslag

Objectives and challenges

  • Replace a largely manual packaging process with a precision-driven automated solution
  • Combine human flexibility with the consistency of robotics
  • Ensure full operational readiness from day one, with minimal downtime
  • Enable secure remote access for maintenance and service updates
  • Demonstrate that operators can be redeployed to higher-value roles

Technical solution

  • SIMATIC S7-1500F PLC programmed in the TIA Portal
  • SINEMA Remote Connect for secure remote access
  • SCALANCE M874-3 and SCALANCE XB216 network components
  • SIMATIC ET200SP and ET200AL I/O systems
  • SIMATIC comfort panels
  • SIMATIC S120 Booksize drives
  • SIMOTICS servo motors
  • SIRIUS switching devices
  • SITOP power supply units

Benefits for Rockfon

  • Successful replacement of manual processes with a smart packaging system
  • Improved product quality and process consistency
  • Lower operational costs through more efficient use of personnel
  • Operators redeployed to higher-value activities
  • Stable and reliable production from day one
  • Fully operational across multiple shifts
  • Proven concept leading to additional machine investments and future expansion
Document
Leaflet ROCKFON_NL.pdf2.96 MB
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