FOOD INDUSTRY

CARR’S FLOUR MILLS – BESPOKE SYSTEM

SYSTEM SOLUTION

In March 2020 Carr’s had increased output by 50% to 167,000 bags of flour per week to meet a retailer’s requirements. A palletising robot was needed to keep the operation running 24/7 without additional staff, while increasing the quality of the stacked pallet.
The solution is the beautiful, flexible and reliable Fanuc M710ic/70 robot with custom made gripper. At a speed of 74 bags per minute, the bespoke system gently palletises the flour to produce neat small Dusseldorf pallets, placing interlayers for increased pallet stability. Designed to a very small footprint for seamless integration with the existing equipment, the robot features an infeed product collation system with two separate safety zones and two palletising positions for continuous operation. This eliminates frequent start-stopping of the upstream bag filling equipment. Once the first pallet is filled with the required amount the robot continues palletising onto the second pallet, and an operator replaces the first one, taking the filled pallet for stretch-wrapping. The pallets are then delivered to the retailer and placed on the floor for customers to pick products directly from the pallet.

KEY BENEFITS

Increase in productivity
Flexibility according to demand
Reliability and minimum maintenance requirements
Optimal utilization of existing space and resources
Excellent construction quality

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Solution

BREWING INDUSTRY

AMSTEL BREWERY HEINEKEN GROUP

SYSTEM SOLUTION

Integrated and fully automated solution for the repacking line includes the following features:

  • Depalletising of full crates
  • Palletising of empty crates
  • Decrating of full crates
  • 1st level packaging of bottles into shrink wrapped multipacks
  • Coding of multipacks (expiry date, lot number)
  • 2nd level packaging of multipacks into shrink wrapped bundles
  • Labelling of bundles (expiry date, description, barcode)
  • Palletising of bundles
  • Stretch wrapping of bundle pallets
  • Supervision and control system

KEY BENEFITS

Increase in productivity up to 21,000 bottles/min
Production cost reduction
Reliability and minimum maintenance requirements
Flexibility and expandability as the system can easily be upgraded and modified to handle new products
Optimal resources utilization (space, manpower, existing equipment and IT)
Errors minimizationFast and accurate after sales support

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Solution

FOOD & DRINKS INDUSTRY

NESTLE – COMPLETE SYSTEM WITH BOX PALLETISING

SYSTEM SOLUTION

  • Receipt of cartons from the outlets of the three packaging lines.
  • Lifting of cartons from the exit level of each packaging line to the transport level of the central conveyance line (approximately 3m above the ground).
  • Merging of all cartons into one central conveyance line.
  • Overhead transportation of cartons from packaging to palletising area.
  • Down lifting of cartons from overhead conveyance level to the level of palletising infeed.
  • Robotic palletising of cartons according to the agreed palletising patterns.
  • Placement of carton interlayers to ensure pallet stability.
  • Merging of palletising lines via a pallet shuttle.
  • Infeed of finished pallets to the existing stretch wrapping line.

    • KEY BENEFITS

    Reliability and flexibility
    Optimal utilization of existing space and resources
    Connection with the existing IT systems
    Expandability thanks to modular design (e.g. the system can be enhanced to handle four production lines)
    Excellent construction quality
    Traceability
    Satisfaction of special requirements (operation mode, materials used, security etc.)
    Personnel and existing equipment security

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    Solution

    FOOD INDUSTRY – MILK

    FRIESLAND CAMPINA – BOX PALLETISER WITH MULTIPLE FEEDS

    SYSTEM SOLUTION

    Integrated and fully automated solution includes the following features:

  • Palletising of tetrapak cartons
  • Two robots to achieve maximum productivity
  • Processing products from 4x productions lines
  • Automatic stretch wrapping for pallets

    • KEY BENEFITS

    Increase in productivity
    Production cost reduction
    Reliability and minimum maintenance requirements
    Flexibility and expandability as the system can easily be upgraded and modified to handle new products

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    Solution

    DETERGENTS & TISSUE INDUSTRY

    ENDLESS – DOUBLE PALLETISER FOR BOXES

    SYSTEM SOLUTION

    At the secondary packaging level, the investment is about fully automating the case packing processes for its two fastest production lines, and semi-automating of the rest. The goal is to fully automate all lines in the years to come.
    At tertiary packaging level, the goal was to gather all the production lines on a central palletising system per line of origin.
    In order to achieve the goal of transferring the palletising processes from the production area to the warehouse area, the six individual lines are merged into one, which transports them all together to the warehouse area.
    The boxes are then sorted based on source line, are being palletised into six distinct palletising positions, before they are driven to a stretch wrapping machine to stabilize them, then to a print and apply system to mark them with a label and finally to the warehouse.

    KEY BENEFITS

    Reliability and flexibility
    Optimal utilization of existing space and resources
    Connection with the existing IT systems
    Expandability thanks to modular design (e.g. the system can be enhanced to handle four production lines)

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    Solution

    TINNED PRODUCTS INDUSTRY

    KYKNOS CAN PALLETISER

    SYSTEM SOLUTION

    Integrated and fully automated solution for the packaging line includes the following features

    Palletising of carton trays with cans

    Stretch wrapping of ready pallets

    Processing 30x trays per minute

    4 different sizes of cans

    KEY BENEFITS

    Reliability and flexibility
    Optimal utilisation of existing space and resources
    Connection with the existing IT systems
    Expandability thanks to modular design (e.g. the system can be enhanced to handle four production lines)

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    Solution

    FOOD & SNACKS INDUSTRY

    INTERNATIONAL FOODS – BOX PALLETISER

    SYSTEM SOLUTION

    Integrated and fully automated solution for 3x lines includes the following features:

  • Robotic palletiser
  • 3x product infeeds and 3x palletising positions
  • Layer collator
  • Mixed layer end-effector tool
  • Automatic pallet positioning

    • KEY BENEFITS

    Reliability and flexibility
    Optimal utilization of existing space and resources
    Connection with the existing IT systems
    Expandability thanks to modular design (e.g. the system can be enhanced to handle four production lines)

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    Solution

    ANIMAL FEED INDUSTRY

    LAKY – BAG PALLETISER

    SYSTEM SOLUTION

    An ‘in a box’ robotic solution, the system is fitted with a bespoke mechanical gripper which is programmed to pick up and accurately palletise bags of varying weights – at a speed of up to 12 bags per minute.
    The robust grippers have been manufactured to handle a wide range of packaging, including hessian and glossy materials.
    The system has been pre-installed with a special mechanism for flattening the bags, making them easier to manoeuvre, while enhancing the stack ability of the pallet.
    The FANUC robotic arm places the bags on to the pallet under a pre-defined pattern which maximises load stability.

    KEY BENEFITS

    Increase in productivity
    Flexibility according to demand
    Reliability and minimum maintenance requirements
    Optimal utilization of existing space and resources
    Excellent construction quality

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    Solution
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