VERSION CONTROL

VERSION DATE CHANGES DONE BY CHECKED BY APPROVED BY

Raúl Benítez Estefanía Garrido François van Rooij
1.0 25/09/2020 New Procedure LELYSTAD LELYSTAD LELYSTAD
PLATFORM PLATFORM PLATFORM

EMPTY BOX
MAINTENANCE
PROCEDURE A5
A1-PED-PAQ-008
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Index
1. OPERATIVE / FUNCTIONALITY.................................................................................................................................................. 2
2. PROCEDURE REVISIONS.......................................................................................................................................................... 8

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1. OPERATIVE / FUNCTIONALITY

The purpose of this procedure is to describe the process/route the boxes follow when they arrive to Empty Box Area (.

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NEW EMPTY BOXES

☐ STEP 01

Operators lift pallets full of empty boxes from the ground floor to the third floor using one of
the two elevators.

☐ STEP 02

Operators load the new cartons in the Lantech box maker (Id. 20184616) located third floor.

This machine erects boxes automatically, thus feeding the system with new boxes.

☐ STEP 03

Zetes MD1500

A labelling machine (Zetes MD1500) attaches a barcode label to identify each box and then a
scanner reads it to enter the code into the management and control system.

☐ STEP 04 The new empty boxes continue along a single line of the Knapp system (roller and belt

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To lower
level

conveyors) leaving the third floor in the direction of the sorters (first floor).

☐ STEP 05

Before the empty boxes reach the first floor, they circulate through the intermediate platform
located on the first floor.

These come by a single line and this is where they are divided into three different routes
To To To depending on which classifier you have to supply.
Sorter 3 Sorter 2 Sorter 1

☐ STEP 06

New empty boxes are finally lowered into the corresponding sorter on the first floor via two
Knapp belt conveyors.

☐ STEP 07

Once the boxes arrive at the sorter, they circulate in a loop on both sides of the sorter, until
the operators take them manually to place a new empty box at the destination chute.

REUSED EMPTY BOXES

☐ STEP 01 The empty boxes reach the third floor from the sorting machines (See previously A1-PED-
PAQ-007 DISTRIBUTION SORTER CONNECTION WITH EMPTY BOXES) once they are

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emptied of garments in the induction stations.

☐ STEP 02

Used empty boxes can be directed to two different checking stations on the third floor.

Both have the same function and are made up of the same equipment.

☐ STEP 03

Boxes arrive at one of the two areas where they receive the first inspection. In each of these
areas there are four checkpoints.

☐ STEP 04

At each inspection station, an operator visually checks the status of each box and decides
where it should be sent by pressing the corresponding button on the control panel:

 TRASH  See Step 06

 REUSE  See Step 05
 CHECK STATION  See Step 09
A Sick scanner located at each station reads the barcode of each box and the system links it
to the destination to which the box is sent.

☐ STEP 05 Boxes that can be reused are sent to the sorters in the same way as new ones.

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See step 04 in the New Empty Boxes section of this procedure.

☐ STEP 06

The boxes that are not in good condition and cannot be reused are sent to the carton trash
located on the ground floor.

The boxes of the different inspection agencies are united in a single line. This runs a long
distance on the third floor via Knapp roller conveyors.

☐ STEP 07

The boxes are lowered by a belt conveyor from the third floor to the first floor. At this level the
boxes continue on roller conveyors until they take the Nerak box elevator.

☐ STEP 08

The boxes leave the Nerak elevator on the ground floor and circulate on the Knapp
conveyors until they reach the garbage containers.

☐ STEP 09 Boxes that are not damaged but cannot be reused directly are sent to the check stations to
be checked manually by the operators.

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The boxes arrive at each check station via two rollers located at a low level and exit via a
conveyor belt that rises to a high level.

☐ STEP 10

There are two check stations in each empty box management area. There operators check
visually boxes damaged and they repair them if is possible.

Repaired boxes will be joined on the route followed by the reused boxes (See Step 05).

Damaged boxes that cannot be repaired will join the trash route located on the ground floor
(See Step 06).

MAINTENANCE

☐ STEP 01

As this is a connecting route consisting of several pieces of equipment from different

suppliers, the maintenance plans and their tasks must be consulted in the following
documentation:

 Knapp Streamline Conveyor Maintenance Plan

 Machine Manual of Lantech Automatic Erecting System
 Instruction Manual of Zetes MD1500
 Operating Instructions of Nerak elevator

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2. PROCEDURE REVISIONS
REVISIONS

Date Version Section Step Comments Validated by

25/09/2020 1.0 New Procedure Estefanía Garrido

APPROVAL

Date Version Section Step Comments Validated by

25/09/2020 1.0 New Procedure François v. Rooijen