For Rockfon, part of the ROCKWOOL Group, ACE development & engineering developed a fully automated packaging line for aluminium T-profiles. The project aimed to transform a largely manual packaging process into an efficient, scalable and future-ready production environment. By combining complex packaging operations, advanced packaging automation, machine building, industrial automation and robotics into one integrated solution, the entire process from packaging through to palletising was successfully automated. This enabled Rockfon to increase productivity, improve ergonomics and create a solid foundation for future production expansion.

 

The challenge

Rockfon continuously strives to further automate its production processes for ceiling systems. Within the production of aluminium T-profiles, a key challenge was the automation of packaging operations. Tasks that are intuitive for operators, such as accurately positioning and packaging profiles into boxes, are technically far more challenging for machines.

The new solution needed to combine the flexibility of human handling with the accuracy, reliability and consistency of a fully automated system. At the same time, the installation had to be immediately operational within a production environment where availability, quality, output and scalability are critical. Rockfon therefore required a solution that would not only improve production automation but also contribute 

The solution

ACE development & engineering developed and delivered a fully integrated packaging automation solution that automates the complete end-of-line process. The installation processes the manufactured T-profiles, accurately positions them into packaging and subsequently performs automatic palletising of the finished products.

The system forms a complete end-of-line automation solution in which handling, packaging and palletising are fully integrated. By combining industrial robotics, intelligent control systems and machine building expertise, a stable and repeatable packaging process was achieved that is suitable for continuous production environments.

The control architecture is based on Siemens automation technology, integrating PLC control, I/O systems, servo drives and network infrastructure into one platform. This resulted in a reliable and scalable installation capable of performing complex packaging movements consistently and accurately.

The packaging line also incorporates secure remote support and maintenance capabilities, enabling efficient management and optimisation throughout the lifecycle of the installation.

"With ACE's technical expertise and Siemens' continuous integration technology, we can rely on being operational from day one."

Carlo Vanschoenwinkel
Director Grid Operator and Logistics, Rockfon
ace development & engineering ontwerp tot realisatie

From concept to completion

ACE development en engineering Rockfon oplevering inpaklijn

Final inspection before handover

ace development en engineering Rockfon tevreden team

A satisfied ACE team

"With ACE's technical expertise and Siemens' continuous integration technology, we can rely on being operational from day one."

Carlo Vanschoenwinkel
Director Grid Operator and Logistics, Rockfon

Our contribution

For this project, ACE development & engineering was responsible for the complete trajectory from concept development through to final delivery.

Our activities included:

  • Concept development
  • Mechanical design
  • Electrical engineering
  • PLC programming
  • Industrial automation
  • Packaging automation
  • Machine building
  • Integration of industrial robotics
  • Machine construction and assembly
  • Commissioning
  • Testing and optimisation
  • Turnkey delivery

By combining machine building, automation, robotics and system integration, a solution was developed that perfectly fits Rockfon's production environment and is ready to support future capacity expansion.

The result

With the new installation, Rockfon has taken an important step towards further automating its packaging processes and end-of-line production activities.

The solution resulted in:

  • Full automation of previously manual packaging processes
  • Improved process consistency
  • Enhanced product quality
  • Reduced physical workload for operators
  • Fewer manual operations
  • Increased production efficiency
  • Stable production across multiple shifts
  • Secure remote maintenance and support capabilities
  • A scalable foundation for future expansion
  • Expanded use of industrial robotics within the packaging process

Scalable packaging automation for future growth

Shortly after commissioning, the installation was already operating at approximately 90% of its intended capacity. The success of the first installation also paved the way for further expansion. Rockfon subsequently invested in additional production lines for high-volume T-profile applications, demonstrating the reliability and scalability of the chosen automation approach.

The solution clearly demonstrates how modern packaging automation and end-of-line automation can contribute to higher productivity, consistent quality and more efficient workforce deployment within industrial manufacturing environments.

EXPERTISE AND TECHNOLOGIES

  • Machine building
  • Industrial automation
  • Packaging automation
  • Production automation
  • End-of-line automation
  • Automation & Robotics
  • Industrial robotics
  • System Integration
  • Control Systems
  • Motion Control
  • PLC programming
  • End-of-Line Automation Systems
  • Packaging Machines and Lines
  • Handling and Conveying Systems
  • Palletising and Distribution Systems
  • Automated Production Lines
  • Palletising systems
  • Smart Manufacturing
  • Siemens SIMATIC S7-1500
  • SIMATIC ET200SP
  • SIMATIC ET200AL
  • SIMOTICS servo motors
  • SCALANCE network infrastructure
  • SINEMA Remote Connect

Project reflection

With this project, Rockfon has taken an important step in further automating its packaging processes and end-of-line production activities. By fully automating complex packaging and palletising operations, a more efficient, reliable and controllable production process has been achieved.

For ACE development & engineering, this project is a strong example of how machine building, packaging automation, industrial robotics and advanced control technology come together in a solution that directly contributes to higher productivity, improved ergonomics and sustainable growth. Through close collaboration with Rockfon, a future-ready end-of-line automation solution was developed that not only meets today's production requirements but also provides a solid foundation for further optimisation, digitalisation and expansion of the production environment.

More information

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Leaflet ROCKFON_NL.pdf2.96 MB
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