Game changing benefits from creative and compact palletising cell

Scott has recently finalised and installed the new Compact Robot Palletising System for a leading personal hygiene company in Australia, supplying a large number of personal care products to Australia, New Zealand and the Pacific markets.

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  • Overview

The customer was looking at automated options in a bid to avoid manual palletising, reducing labour costs & increase operator safety on a newly installed line. They were looking for a compact system occupying a small footprint, which was cost effective and easily accessible by operators. This system would also need to be implemented quickly with minimal disruption to the existing production.

Scott had previously installed a different palletising system for this customer previously. This positive experience combined with our existing knowledge of the site and flexible approach made Scott a logical choice for the job. Being a recognised key integrator for Kuka enabled Scott to acquire a robot for the system sooner, compressing the timeline for delivery. A benefit that appealed to the client over other automation providers.

Various options were explored with the customer and the resulting solution provided a system that could have a full pallet removed without stopping. This new system was the new Compact Robot Palletiser, a fully automated end of line solution to palletise products in dual cells. Able to palletise up to 30 cartons per minute with a maximum height of 2.4m the system could be implemented quickly and with very little impact on the existing production lines.

The customer is very happy with the system particularly as they have experienced a good return on investment. They were pleased with the speed of the response from Scott, from initial contact through to delivery was 14 weeks. The install had no impact on their existing production line and being safe and easy to operate as well as easy to maintain has surpassed the expectations the customer had of the Compact Robot Palletiser.

System Overview

An operator places an empty pallet into both sides of the robot cell. The system is designed so the operator can see when it is safe to enter the cell with the indication of a green light. Light curtains on entrances to both cells protect the operational zone. Once the pallet is in the cell an operator selects the pallet pattern and starts production. The robot then picks one of 2 case types (though only 1 is ever run at a time) and then the robot places in the correct pattern on the pallet in the cell in use.

Once the pallet is completed, the reverse guillotine safety guarding will raise, safely separating the cell from the robot the allowing the operator to remove the completed pallet while the robot continues palletising in the second cell. This dual cell system meant that there was no disruption to the production line and the safety systems in place gave the operators access to the cells when they weren’t in use.

Benefits

  • Significant cost savings through automation over manual labour
  • No downtime or disruption on existing production lines during install or when in use
  • Fast delivery of system
  • Compact system, has a small footprint within a factory
  • Reliability of the robot system
  • Product handled with automated repeatability
  • Reduced product damage
  • Increased operator health & safety
  • Reduced risk of damaged product in transit

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