Vacuum Solution Improves Ergonomics for Handling Eggs

The company has been moving, processing and distributing this sensitive commodity for more than 100 years. Today, Lüchinger + Schmid AG is the market leader in Switzerland. The company is part of the Micarna Group, which in turn belongs to M-Industry. Up to 80 million eggs are processed every year in the tranquil town of Flawil in the eastern Swiss canton of St. Gallen. In total, around 140 people are employed by Lüchinger + Schmid AG. The twelve employees in the sorting department in Flawil pack around 300,000 free-range and organic eggs daily, which are delivered the same day to retail outlets in the surrounding area.

Handling and processing eggs along the entire supply chain is a challenge: from collection, through processing to delivery. Due to the freshness of the product, the work must be done very quickly – a standstill is an absolute no-no. After delivery, a machine checks the goods for damage and contamination and sorts the eggs into different packages according to size. The employees then sort the packages into containers and pass them on for palletizing.

The company particularly saw potential for improvement in the last step of the handling process in Flawil, when the various containers are sorted from the packaging conveyor belt onto pallets. Employees had to lift the boxes or cartons weighing 15 to 25 kg by hand and place them neatly on the pallet – up to a height of 1.80 m. As the number of containers increased, this work also became more physically challenging for the employees, making a more ergonomic design of the work area essential. “The entire Micarna Group attaches great importance to an ergonomically equipped workplace. After all, satisfied and healthy employees are an important success factor,” says Patrick Nyffenegger, Technical Project Manager at Micarna SA.

A visit to EMPACK in Zurich, one of the most important Swiss trade fairs for new products, innovations and trends in the packaging industry, provided the impetus for the solution. René Schürch, Head of the Packing Center at the Kloten site and Dominik Gmür, Head of Operations at the Flawil site, found their attention drawn to Schmalz GmbH and its products for handling containers. The demonstrations at the fair, where contact was first made, highlighted the potential of vacuum technology. Together with Patrick Nyffenegger of Micarna SA, they decided to consult Schmalz in the search for a solution for improved ergonomics.

Christian Fluri, Managing Director at Schmalz Switzerland, took up the challenge and proposed a solution tailored to their local circumstances. A customized offer to suit the needs of Lüchinger + Schmid AG spelled success for Schmalz. During a visit to Flawil, Christian Fluri took a close look at the situation and subsequently presented a flexible solution adapted to the process. In this case, he decided against a ceiling suspension and instead recommended a gantry crane system for the work area. The supports occupy very little floor space. The JumboFlex 25 vacuum lifter now performs its tasks using the aluminum crane system attached to it. The vacuum lifter is equipped on the one hand with a gripper developed specifically for the customer to handle Migros’ own crates. An integrated quick-change adapter allows quick replacement of the grippers. Employees can then also transport cartons filled with eggs using the same vacuum lifter. “The conversion is easily mastered,” explains Dominik Gmür. He also greatly appreciates the radio remote control system, which the employees use to switch the appliance on and off quickly – saving valuable energy at the same time.

Micarna SA also attributes great importance to the after sales service delivered by its suppliers. Another Schmalz installation at the Kloten site has been running smoothly for almost two years now. “However, we still appreciate the availability of a reliable contact and prompt supply of spare parts. In this regard, our cooperation with Schmalz is as pleasant as it is uncomplicated," says Nyffenegger. He describes service and after sales as the supplier’s calling card, which has left a lasting impression on him.

The employees took to the system very quickly, not least because it is very easy to operate and the training only took a short time. “The goal of improving the ergonomics of the egg palletizing process was definitely achieved. Our experiences with the tube lifter have only been positive so far. Especially when it comes to heights above 1.60 m, the system lightens our employees’ load tremendously, and they no longer have to use all that momentum to stack the containers. They can now lift the crates onto the pallets in a controlled and well-regulated manner. Our employees are very satisfied because the physical demands on them are significantly lower and the processes are easier and more orderly,” says Dominik Gmür.

There is also much praise for their collaboration throughout the whole project. All requests were taken into consideration and uncomplicated solutions were quickly found. “The entire flow of information including quotes, delivery deadlines and processing also went smoothly,” says Gmür, praising the teamwork with the vacuum specialists.