Upcycling automation systems can result in savings of up to 40%

In the world of automation, too, it can sometimes pay to upcycle. Our customers know this well, which is why BoConcept has once again invested in an automation solution made up of several used units.

It isn’t always necessary to invest in brand-new machines. In fact, it’s perfectly possible to get a custom automation system where either the entire system or parts of it consist of recycled components. In this case, the system was put together in collaboration with the customer, who already had a crusher that was integrated into the finished system. This also made it possible to have the entire system CE-marked by Gibotech.‍

Not just for the money

Opting for partial upcycling of hardware is nothing new for BoConcept, which has previously purchased used machines and robots. This approach is closely aligned with the company’s efforts to implement initiatives that prioritize people and the environment.

Our overarching goal is to manufacture our products with as little environmental impact as possible, and we are constantly working to improve our environmental performance in both production and logistics. That is why it makes perfect sense for us to implement a solution consisting of used machines and robots.

Kim Sejbjerg, Plant Manager at BoConcept‍

Significant savings and a long service life

It’s not in software and programming where the savings come from when building new facilities through upcycling. The cost is essentially the same, regardless of whether the machines and robots are new or used, when it comes to software and programming. However, there are significant savings to be made by using and integrating used hardware into a new system. In this case, BoConcept achieved a 40% savings by choosing a used CNC machine and robot.

So don’t be afraid to think in terms of upcycling when embarking on an automation project. Gibotech uses only internationally recognized suppliers to ensure that machines and robots have a long service life. In fact, several of the systems the company installed in the early 1980s are still in operation today. As an extra safeguard—regardless of whether the system consists of new or used robots and machines—you should always consider setting up a service agreement for the system. Regular service checks and maintenance can be scheduled around production and minimize the risk of downtime.

- The first system we purchased from Gibotech dates all the way back to 1987, and it’s still running flawlessly. Back then, we invested in brand-new CMS-CNC machines, and we’ve had no problems whatsoever. That’s why we’re not worried about upcycling this time either, because we know these systems can last for many years. And of course, we’ll make sure to set up a service agreement with Gibotech so that, with regular service checks and maintenance, we can keep our new system running for many years to come, says Poul Brændgaard, Project Manager at BoConcept A/S.

Crusher, CNC, and automated machine operation

In addition to the customer’s crusher, the system consists of a fully refurbished CNC machine from 2001 and a used Fanuc M410iB robot from 2008.

The used CNC machine is a CMS PF102 that was refurbished with, among other things, a completely new OSAI control system, including new cables, axis cards, and servo motors. In addition, the machine was equipped with a new PC and control panel. As part of the refurbishment, the robot was fitted with a new gripper that can handle workpieces securely and with a firm grip, ensuring the workpiece does not shift when rough-milled by the robot.

The entire system is designed as an automated solution, in which the robot first rough-mills the workpieces on a milling spindle mounted above the crusher. By rough-milling the workpieces before they are loaded into the machine, large pieces of scrap are prevented from ending up inside the CNC machine, leaving only chips that can be vacuumed away. This also avoids unnecessary stoppages to remove pieces of scrap.

The system also includes a used laser projector designed to project images of the workpieces or vacuum cups onto the CNC table, allowing the operator to quickly position the vacuum cups correctly and thereby reduce setup time. Once the workpieces have been machined, the robot removes them from the CNC machine and places them on a conveyor belt that transports the finished and stacked workpieces out of the system. The CNC machine has two tables, so it naturally operates in alternating shifts.

- It’s always fun when customers challenge us to think outside the box. We usually sell new machines, but it has been a pleasure to work with BoConcept on creating a comprehensive solution based on upcycling and helping them become more environmentally responsible in their production, concludes Henrik Thomsen, Product Manager, CNC at Gibotech.