
- Home
- News & Newsletter
- ferag.skyfall at Alcon: A Technological Collaboration Driving Logistics Innovation
ferag.skyfall at Alcon: A Technological Collaboration Driving Logistics Innovation
Hinwil, 10.12.2024 – Alcon, a global leader in eye care, specializes in products and technologies that enhance vision and improve patients' quality of life. Since its founding in 1945, the company has offered a wide range of solutions, from contact lenses to advanced surgical equipment.
Ferag has completed the installation of its ferag.skyfall system in Alcon’s production facility in Puurs, Belgium, which is dedicated to preparing ophthalmic surgical products. These products are assembled according to surgeons' specific needs and include all the instruments required for precise procedures.
An Innovative Solution for Complex Logistical Challenges
The integration of ferag.skyfall at Alcon was driven by a crucial need: to optimize a production area with a dynamic storage solution that fits into an already confined space, boosting productivity and quality control. Traditional solutions for temporary storage were either unsuitable for these constraints or less effective in terms of production flexibility. The ferag.skyfall system proved to be a compact and flexible alternative, intelligently utilizing unused building space and offering exceptional efficiency and reliability. It enables the transport, storage, and sequencing of products for optimal flow management. This project comprises three subsystems: a conveyor system for automated loading, dynamic storage, and end-of-line equipment (for packaging into cartons), including palletizing and wrapping.
The ferag.skyfall system includes two automatic loading stations to fill the pouches that transport the products to rotary conveyors for dynamic storage. These pouches are selected on demand according to production needs and transferred to sequencing lines before being sent to the cartoning area. This system was installed along a 60-meter corridor with a height of 10 meters and a width of just 5 meters. The space is optimized through dynamic buffers on two levels, with a three-level sequencer below, making a total of five levels for storage and sequencing. This design manages more than 1,500 items per hour from production and effectively absorbs activity peaks. Moreover, this innovative solution reduces repetitive tasks, optimizes flow management, eliminates internal pallet movements, and thereby reduces associated risks.
Towards a Smoother Production Process
Products are fed into the dynamic storage at a rate of up to 1,600 pieces per hour and transported via belt conveyors to the two automatic loading stations of ferag.skyfall. Before loading, each product is scanned and automatically placed into one of the system's pouches and transported to the dynamic buffer, which can hold up to 2,700 pouches.
At the output, four sequencing stations direct products to one of the two automatic pouch unloading stations. Up to 1,500 pouches per hour can be emptied at the two unloading stations, where the products are packed into cartons. These cartons are then automatically sealed, palletized, and wrapped, ready for shipment. The material flow is designed to maximize efficiency, with high production capacity and rapid responsiveness to changing demands.
The system, designed for a tight infrastructure, integrates seamlessly with existing systems. Optimizing available height and intelligently automating connections between transport, storage, and sorting areas were critical aspects that reduced the need for manual transport and associated risks.
A Partnership Built on Trust
The success of this project is based on a trusted partnership between Alcon and Ferag, initiated in 2021. Convinced by the performance of ferag.skyfall, Alcon signed the contract in November 2022. The system was installed in Fall 2023, with production scheduled to begin in Spring 2024.
“The collaborative partnership was exemplary, with mutual trust allowing each party to fulfill its responsibilities and achieve a shared success,” says Eric Audemars, Sales Director at Ferag. The technical solutions met Alcon’s expectations perfectly, delivering optimal results. Throughout the project, consistent transparency and adaptability enabled the development of a customized solution aligned with the client’s needs.
“Trust was established through our team’s conviction in the solution’s potential. This confidence is contagious and translates into tangible results. That’s what the client experiences throughout the project, and it’s what makes the difference,” concludes Eric Audemars.
Ferag and Alcon illustrate how cutting-edge engineering and a strong partnership can turn logistical challenges into high-performance, sustainable solutions.