PACEPACKER has announced it has helped to more than double the output for a global hand hygiene supplier by automating the case erection, loading and palletising tasks previously performed manually
In what the firm described as one of its most “complex, largest and innovative projects”, Pacepacker devised a solution comprising 15 individual elements, the use of 3D technology and products from nine different original equipment manufacturers (OEMs).
Wanting to improve the versatility of its plant and increase line packing speeds, Pacepacker was brought in to automate two manual packing production lines and palletising operation, creating a centralised, fully automated turnkey line. By solving the factory’s reliance on multiple workers overseeing each packing element, Pacepacker estimates that it will cut annual workforce costs by around £400,000 a year.
One of the key challenges was that the packing line needed to handle up to six different wholesale-sized occupational hand sanitiser bottlers, plus a combination of 70 pallet types and stacking patterns.
Pacepacker said that, done manually or automatically, picking up bottles and placing into cardboard outer sleeves can make it difficult to insert the last product into the box. Pacepacker designed an automated option that picks up an entire layer of product, adapting itself to the exact quantity of bottles required per box. Paul Wilkinson, Pacepacker’s commercial and information systems manager said, “While layered product loading is feasible for lighter weight and delicate product types, heavier items like bottles are typically loaded into cases individually or in smaller quantities.”
To maximise efficiency, Pacepacker designed two packing lines feeding one palletising robot. A simple capture automation vision system checks the barcode and checks bottle caps are secure. This is followed by a Thermo Fisher conveyor-style checkweigher and an Endoline case erector, which automatically tapes each case bottom to form boxes for loading.
The software-driven adaptable robot end-effector grabs hold of the top of each bottle in one layer in a four, six or eight bottle format. Meanwhile, Pacepacker’s case loading flap opening device, located beneath the conveyor, holds all four box flaps 10mm clear of the loading operation. This helps to stop flaps becoming inverted during the loading process.
“The end effector is a truly innovative and unique feature,” Paul added. “Around 70% of case loading applications use vacuum, yet as there’s no significant area on the top of each sanitiser bottle we designed a mechanical solution that grabs hold of the top of each bottle in two rows, in one movement.”
Pacepacker believes this could be the UK’s first installation of an adaptive gripper that picks up and gently places a full layer of heavy bottled products (weighing between 1kg and 4.5 kg each) into boxes using this method.
In order to create this end-effector, Pacepacker used 3D modelling printing technology. “In many applications we now use 3D to create specific tooling, fixtures and grippers rather than relying on standardised components. In this instance, we sculpted and 3D printed a gripper to suit the handle of the bottles being picked up,” Paul added.
Replacing the customer’s traditional roller manual palletising conveyor operation, Pacepacker designed a robotic palletising cell featuring two pick conveyors and two pallet conveyors. They used a high payload FANUC 4-axis M410-iC/85 robot, which picks up and places wooden pallets into position and lifts up to three boxes in each movement, placing onto pallets in the programmed format. The cell can palletise up to two different SKUs at a time.
Costing over £500,000, the cell took eight months to design and engineer and measures 330 square metres. Pacepacker said cycle speeds on each secondary packing/case loading line have increased to between 35 and 60 bottles per minute, compared to 24 bottles per minute when manual packing and using automation to load bottles into cases individually.
