MadejPak delivered four major automation projects for Dankoal. The first was a complete disposable grill packaging line — from automatic charcoal weighing to neat tray rim folding. Subsequent phases covered charcoal and briquette bagging machines, non-standard paper packaging and a firelighter packaging line.
Starting situation
The entire packaging process was performed fully manually: hand-filling charcoal into disposable grill trays, inserting the grill grid and manually folding the tray rims. The process was very slow and inefficient.
Challenge
Phase 1: design and build a complete line from scratch, automatic and neat tray rim folding without product damage, demanding environment (charcoal dust). Phase 2: machines for collecting and sewing the customer's paper bags, specialist palletisers with a mixing gripper. Phase 3: vertical machine adapted for non-standard packaging material (paper coated with heat-seal film). Phase 4: collection of paraffin-soaked firelighters, cooling and flow wrap packaging.
Project scope
Phase 1: complete disposable grill packaging line — automatic charcoal scales, label dispensing, automatic tray rim folding
Phase 2: 2 machines for charcoal and briquette bagging with paper bag sewing + 2 flat-plate palletisers with mixing gripper
Phase 3: vertical packaging machine for charcoal in non-standard packaging (paper coated with heat-seal film inside)
Phase 4: firelighter packaging line — collection, cooling and flow wrap packaging on a GSP 50 with product magazines
Implementation results
Full automation of a previously fully manual packaging process
Significant throughput increase at each stage
Attractive, repeatable packaging ready for retail
Handling a wide range of grill products in a single plant
Technologies & solutions
Complete disposable grill packaging line (MadejPak in-house design)
Bagging machines with paper bag sewing
Flat-plate palletisers with dedicated mixing gripper
Vertical machine for non-standard packaging material
GSP 50 flow wrap with product magazines
Technology partners
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