COMPLEX
MANOEUVERS

Rockfon from Wijnegem is part of the ROCKWOOL Group. They produce fire-safe and acoustic suspended ceilings and components for this.

Rockfon wanted to automate the entire production process and make everything work together seamlessly from start to finish. From profile production to stacking boxes. Automation of the packing process was not easy: complex manoeuvers that a hand can make effortlessly, for example putting something in a box, are a lot more difficult for a machine.

ACE development & engineering has not only increased productivity for Rockfon. Also safety, ergonomics and workability have been given a major boost.

FULL
AUTOMATION

Initially, the aluminum T-profiles were still manually inserted into cardboard boxes. A labor-intensive and straining job. ACE fully automated this packing process. This project involved developing the packaging installation for Rockfon from A to Z:

  • concept definition in collaboration with Rockfon
  • mechanical and electrical design
  • PLC programming
  • project supervision
  • construction of the machine
  • testing

After the products have been packed in boxes, these boxes are palletised using a robot installation.

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
To references To industrial automation