Customized gripper component optimizes handling process for self-adhesive carpet tiles

Innovative solution increases productivity and process reliability.

Gierecker & Brökelmann, a German specialist in machine construction, has developed a handling solution for a leading carpet manufacturer that makes the production process for self-adhesive carpet tiles significantly more efficient and reliable. The heart of the system is a custom-modified needle gripper from FIPA.

The challenge

During the production of carpet tiles, rectangular (1,000 × 250 mm) or square (500 × 500 mm) carpet tiles are punched out of a carpet strand. Each punching stroke produces eight carpet tiles. However, the self-adhesive layer on the underside of the carpet tiles, which is used for fixing them in place later, makes it difficult to remove them from the punch. Previous gripper solutions quickly reached their limits here, as the necessary tear-off force could not be guaranteed.

The solution

A modified version of the GR04.725 needle gripper from FIPA is used. This needle gripper has 32 needles as standard. In close consultation with the customer, the number of needles per gripper was reduced. Fewer needles per unit enable greater penetration into the approximately 7 mm thick carpet backing. This ensures that the needles reliably penetrate the stiff felt backing, pull the carpet tiles safely and without damage from the conveyor belt, and then release them from the pile without any problems.

The result

The solution was impressive across the board: every 7.5 seconds, eight carpet tiles are automatically picked up, separated and stacked in a defined packing pattern. Processing both tile sizes with the same system increases flexibility and reduces changeover times. At the same time, process reliability has been significantly improved, as the carpet tiles are picked up, separated and stacked precisely without damage.

Process reliability: Consistently high quality with every cycle
Productivity: One carpet tile is processed every second
Flexibility: Both square and rectangular carpet tiles can be processed using the same handling device
Sustainability: Replaceable needle plates extend service life and reduce material usage

„By customising the needle gripper, we have not only increased the customer’s productivity, but also taken process reliability to a whole new level“, explains Hubert Rueschenbeck, Managing Director at Gierecker & Brökelmann. „The customer was so impressed with the solution that another system is already planned for conversion.“

The idea for the customized gripper solution was developed in close cooperation with FIPA’s field sales team, who addressed the problem individually and significantly advanced the project with their practical experience. The project shows how customized special solutions can optimize production processes and set new standards in efficiency and quality.

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