Revolutionizing Packaging: Robotic Palletizer Supercharges Efficiency

A leading corrugated box manufacturer wanted to automate a labor-intensive palletizing task, aiming to improve plant efficiency and address worker shortages. The manual process involved handling seven different box sizes, each with unique stacking configurations. Worker safety was a top priority.

ACS engineers, certified in Kawasaki robotics, designed a custom robotic solution. The system featured an end-of-line conveyor, a modified robot with a specialized end effector, and an integrated controller pendant. The robot efficiently handled the variety of box sizes, with adjustments to clamp pressure and depth to protect product integrity. Additionally, programmable suction cups were installed for slip sheet placement between layers.

To ensure safety, the robot operates within a fenced area equipped with proximity switches, door locks, and a light curtain for automatic shutdown if accessed. The entire system is managed through a user-friendly controller, eliminating the need for additional PLC systems.

The solution reduced the labor requirement from three workers to two and eliminated the need for frequent shift rotations. ACS also programmed the robot for future flexibility, allowing easy integration of new product profiles. The immediate success of the solution prompted the client to purchase a second robotic palletizer for another line, further enhancing their operations.

FAQ Spotlight

Your Most Common Question Answered

Q: We want to integrate more robotics into our manufacturing plant but have safety concerns.

A: When introducing robotics, integrating the right combination of physical and PLC safeties mitigates potential hazards to maintain a safe environment. Any automated system, especially robotics, should undergo a thorough risk assessment at the front end of the design process. This ensures the design incorporates safety measures as early as possible, preventing costly retrofits and minimizing disruption to operations.