A UK flour mill has strengthened its automation strategy with the installation of a new robotic palletising and conveyor solution from Endoline Robotics.
Replacing an older system that could no longer meet growing demands for flexibility and throughput, the new solution is capable of handling up to 14 bundles of flour per minute across two production lines, which is the equivalent of between 56 and 168 individual bags of flour every minute.
Designed to work alongside an existing Endoline palletiser dedicated to one of the site’s two production lines, the upgrade forms part of a broader automation strategy. The mill operates two filling lines producing individual 1–2kg bags and larger 18kg shrink-wrapped bundles. The original system, installed five years ago, manages the individual bags from Line 1. This left Line 2’s individual bags, together with the bundles from both lines, requiring a more flexible palletising solution.
Engineered to accommodate both product formats, the system also incorporates the automatic handling and placement of wax paper interlayer sheets.
The project was driven by the need to overcome limitations within the previous palletising operation, which lacked the flexibility to efficiently handle varying bundle sizes and evolving product formats. As the mill expanded its product range and customer requirements for bundle sizes became more diverse, a more adaptable solution was required.
The system enables both bundled flour products and individual packs to flow from packing through to pallet build. By automating what were previously labour-intensive and physically demanding tasks, the flour mill is said to have improved operational efficiency, consistency and working conditions.
At the heart of the system is a palletising solution capable of managing product streams from the two filling lines. Bundles and individual packs are transferred via a series of accumulation and transfer conveyors, designed to buffer product flow and maintain a continuous feed into the palletising area without disrupting upstream packing operations.
While the palletiser can manage the simultaneous pick-up of bundled products from both lines, it requires a ‘straightforward’ re-tooling process when switching to palletising individual packs of flour, which are fed down the middle conveyor.
“Our customer needed a solution that could replace their existing palletising system with something far more adaptable and capable of supporting long-term growth,” said Suraj Patel, UK sales manager, Endoline Robotics. “By integrating high-speed palletising with a tailored conveyor layout, we’ve delivered a flexible operation that can handle different product formats, varying bundle sizes and increasing volumes.”
