A manufacturer of adhesive products faced the challenge of significantly increasing the productivity of its self-adhesive film cutting machines. Until recently, these machines had to be stopped whenever operators entered the hazardous area to replace full containers of cut stickers. The manufacturer’s engineering team needed a conveyor system capable of automatically transporting the stickers out of the danger zone, thus eliminating the need for employees to enter it.
The solution provided by mk — a belt conveyor with a timing belt and integrated vacuum function — proved to be the optimal approach for transporting the cut adhesive film safely out of the high-risk area.
This type of vacuum belt conveyor is a specialized solution, typically used in industries such as pharmaceuticals, cosmetics, food processing, packaging, and printing.
How the Solution Works
mk engineers designed a 2000 mm-long ZRF-P 2000 timing belt conveyor with a cantilevered end extending 800 mm into the hazardous zone.
A key feature of the conveyor is the vacuum chamber system integrated within its frame.
A special pattern of openings in the belt and the generated negative pressure securely hold the film in place as it moves along the conveyor.
The conveyor is divided into three zones along the direction of movement:
- In Zone 1, where the film enters, the products are vacuum-held and transported directly from the cutting machine while suspended.
- Zones 2 and 3 are located outside the hazardous area, where pulsed compressed air is used to release the stickers into the designated storage containers beneath the conveyor.
This setup enables employees to safely replace containers without interrupting production.
Smart Design and Energy Efficiency
Another key advantage of the ZRF-P 2000 is its extremely quiet operation.
mk engineers divided the vacuum system into individual chambers — three longitudinal and three transverse.
Sensors detect the position of the cut film and automatically activate or deactivate specific zones.
Thanks to this zoned control, there is no need to operate one large vacuum area continuously pulling air through all the belt openings. This allows the system to work more efficiently — with reduced power consumption, lower energy use, and minimal noise levels.
Flexibility and Ease of Integration
The manufacturer of self-adhesive film also benefits from the mobility and flexibility of the ZRF-P 2000.
The lightweight aluminum frame is mounted on wheels, allowing operators to easily move and position the conveyor next to other cutting machines when needed.
The modular profile design enables stepless height adjustment in just a few steps for smooth alignment.
The vacuum zones can also be flexibly configured for different production lines:
If stickers exit the cutting machine in two lanes, vacuum is applied only to the two central perforated sections. The outer lanes can be activated when the machine outputs four lanes of cut adhesive film.
Since this was a pilot system for testing various application scenarios, the vacuum mode was initially controlled manually.
During the testing phase, engineers measured parameters such as conveyor cycle times, which can be precisely synchronized using a timing belt drive.
Additional sealed connections were also included at the rear of the conveyor to enable the integration of extra vacuum chambers if needed.
Key Advantages of mk Vacuum Belt Conveyors
- Continuous operation increases system uptime – the cutting machine runs without interruption
- Quick return on investment – higher productivity rapidly offsets initial costs
- Flexibility – mobile design easily adapts to various cutting machines in terms of height and throughput
- Safe transport – materials remain stable even at high speeds
- High precision – ideal for processes requiring accurate positioning (e.g., labeling, printing)
- Hygienic design – suitable for cleanroom environments in pharmaceutical, cosmetic, and food industries
- Easy integration – can be seamlessly incorporated into existing production lines
At Robotec, we embrace challenges!
Our goal is to find the ideal solution for every application.
By combining high-quality products from renowned brands, our technical expertise, and creative engineering approach, we deliver maximum value to our clients.
Contact us today to find your trusted automation partner — and discover safe, flexible, and efficient solutions tailored to your production needs!
EN_GB 
BG