(Re)Designing 2 film pack assembly lines Polaroid GO
Market: Industry
"Polaroid GO" is Polaroid's instant film camera. Polaroid commissioned Tebulo Engineering to (re)design two film pack assembly lines. The setup of these assembly lines had to run parallel to the development of film composition and camera development. The project was completed entirely on schedule, and we also provided guidance and advice during the implementation of the assembly lines.
Technology & Activities
Techniques:
- 3D Measuring, 3D/CAD Drawing, 3D Animation & 3D Modeling
- Machine building, Mechanical engineering & Construction
- Control & Automation
- Electronics
- CE Regulations
Activities:
- Basic, Detailed and Site Engineering
- Purchasing (Procurement) and Work Preparation
- On-site construction
- Commissioning
- Maintenance
- Design, Feasibility studies, Concept, Basic & Detailed Engineering
- Strong Calculate (EEM),
- FAT & SAT
- Procurement
- Commissioning, Construction management
- Specifying and supervising the tender process
- Process optimization
- Project management, Project guidance, Advice, Planning, Testing & reporting
Project description
Over the past few years, Tebulo Engineering and a team of engineers have completely redesigned two old Filmpack assembly lines, each approximately 30 meters long, for Polaroid Film BV in Enschede, for a new, previously undeveloped filmpack format. The new filmpack format is approximately the size of a credit card. This filmpack can be installed in the now globally available instant camera known as the "Polaroid GO." 
Polaroid developed the film composition and camera itself, but for the large-scale production of the film packs, the engineering was outsourced to Tebulo. Our engineers were asked to convert two old assembly lines, one of which was already out of service. After analyzing the lines and studying old production drawings, the operation was understood and work began on redesigning and partially improving the lines.
A film pack assembly line can be divided into 7 sub-processes:
- Web Section
- Pack Section
- Packaging Equipment
- Battery/Dummy and Spring Feeder
- Outside Lightseal Attacher (OSLA)
- Darkslide
- Pod Machine (stand-alone)
Each subprocess was set up as a 3D model, with the necessary adjustments immediately mapped out. In the Web Section, a ribbon of photos is assembled, ultimately producing 180 photos per minute. The Pod Machine supplies the developing fluid for this process. The individual photos are combined in the Pack Section, along with the Feeders, Darkslide, and OSLA, into a light-tight cassette containing 8 photos. All of this takes place in the dark.
Ultimately, each cassette is packed and pelletized in the Packaging Equipment process outside the darkroom. During the engineering phase, manufacturing could also begin in parallel. Assembly and control were then handled by a local contractor, but support in requesting parts, as well as during the construction and testing of the line(s), was provided by Tebulo's engineers.
After approximately two to three years of work with a team of creative engineers, we succeeded, exactly on schedule, in building two extremely reliable assembly lines. Polaroid even stated that these are the best-running and most reliable assembly lines they currently have. Thanks to the excellent and intensive collaboration between Tebulo Engineering and Polaroid, we successfully completed this project together.