Packaging Industry Robotics Application

Robotics is being used effectively in the packaging industry to replace humans for simple, repetitive or dangerous work. In theory, robots can work non-stop, with high efficiency and no injuries. For a long time, "robot" seems to be the name of the future. It first appeared in the script of Rossum's Universal Robots written by Czech author Karl Capek in 1920. But the ending of the story was a number of robot uprisings that eventually replaced their masters and wiped out humanity. However, the future still predicts an optimistic distance. The tamed robot takes care of our daily life. Although the current automation is not yet popular, there is no doubt that factories are using robots in large quantities and a new revolution is proceeding quietly. The American Robotics Association (RIA) reported that North American robot companies received nearly $700 million in new orders last year.

Application of robots in production packaging

In many ways, the packaging industry is the pioneer of applied robotics technology. There are many new improvements in robotics technology, but it is not a simple matter. Installing robots in factory buildings requires arduous planning, implementation and adjustment.

The Pepperidge Farm factory installed several robot systems in 1988. One system has 16 arms for clip products, and the other system has 18 arms for packaging. Until now, the two systems have been operating for 50,000 hours in total, except for maintenance.

SIG Doboy Presto Feed Locator

David Watson, Vice President of Engineering at Pepperidge Farm, said that there are two difficult application technologies that exceed the capabilities of robot vision and control. These application technologies require months of development and difficult learning. As a pioneer in automation technology, it provides technology and experience sharing to develop new robotics technology that is easier to program, install, and is faster and more reliable. Today, Pepperidge Farm has installed 90 robots and is responsible for packaging and production.

Among the suppliers, Pepperidge Farm is a customer of Flexicell Inc. Flexicell Inc. supplies robotic equipment and packaging and loading technology to the food, beverage, health care and consumer durables industries. They blended Adept Technology of San Jose, California with North American Fanuc Robotics and other technology products from Rochester, Michigan.

According to Watson, Flexicell solved the problem of efficient packing of Pepperidge Farm. Multi-axis robot packaging equipment, according to different packaging materials, up to 40-50 cycles per minute. With a calibrated conveyor belt, the device can reach up to 200 bags per minute.

Pepperidge Farm also installed robotic packaging kits with visual devices that can identify and inspect products. Using the light source and lens, the system can find out where the product is on the conveyor belt and determine if the product is consistent. During the production process, unqualified rejects and good products can be identified and selected at any location.

Bottle technology

Schneider Packaging Equipment of Brewerton, New York, is another outstanding supplier who can contract the entire line design, with products, services, boxing, automatic palletizing and warehousing. Schneider also produces and assembles other accessories such as conveyors, lifts and packaging components, pallet dispensers, sheet dispensers, and reciprocating continuous load working machines.

One of Schneider's main customers is Puerto Rico's plastic bottle manufacturer. They used robotics three years ago and found the most suitable packaging process for bottles.

An executive of the company said: “Our previous production lines required a lot of labor, each product needed, four full-time employees, another product needed another four, the production process needs to manually add a piece of two layers Due to the use of old machines, the sheets often cause the containers to fall, and then the goods are to be reorganized.The new automated machinery will accurately place the sheets in the required position each time, and can operate two different products at the same time, saving many places. Basically, this is an accurate loading equipment that can be used 24 hours a day, 7 days a week, with very few people."

The executive reported: "This set of equipment continues to provide a high level of efficiency. Since the reference does not require much maintenance, quality and technology are important factors in the selection of automated machines. The experience gained can also be applied to other packaging departments."

Motoman robots provide high flexibility for palletizing

According to the company's robotic system sales engineer Izzat Hammad, the device can be used with other company accessories and arm-end tools to solve the final palletizing problem. Increasing the payload can achieve reliable and sturdy operation and freedom of movement at the joint. The company also uses robots for pick-and-place, packing, unpacking and other tasks.

Another company with innovative design is Robotic Solutions, a Blue Print automatic equipment group of Colonial Heights. Their visual robots are designed for packaging, production and integration in the consumer goods industry.

Martin Prakken, chief executive of Blue Print, predicts that this industry will have more innovations, efficiency will be higher, and is now going to be three-dimensional, if equipped with a better visual system will mean more efficient production.

Inspection system

As robotics technology continues to advance and apply to various industries, suppliers warn to review the entire production process, and in some cases reorganize the system to cope with each innovation opportunity.

Bill Donohue, president of "Automatic Production Systems Co., Ltd." in New Freedom, said: "Customers must pay attention to the reliability of the system and cannot only pay attention to the reliability of the robot. A successful robot system must consider both the design of the system and the quality of the auxiliary equipment. Reliability includes how upstream components transport and fix materials to robots and how downstream facilities handle finished products."

Robots must always be associated with upstream and downstream programmable controllers (PLCs). Effective programming of the controller can enable the robot to achieve satisfactory efficiency. In automated packaging, systems such as robots, upstream and downstream pick-ups must be properly coordinated.

Smart machine

As described by science fiction, some robots have smart features. North American FANUC Robotics has developed a new generation of M-410iB series of palletizing industrial robots. The series has high performance, user-friendly installation, high speed, precision, and high payload.

In different users, this production line is not just a one-dimensional machine that does some specified work according to the program. It can accept any number of jobs. It knows how to think, and can change its operation with different requirements. If equipped with other equipment, the robot can handle a wide range of sizes, tray patterns and up to 30 payloads per minute.

Almost all vendors emphasize speed. For example, the SIG Doboy in New Richmond promotes a range of packaging machinery, from packaging machines to feeders and handling machinery. The Presto Feed Placer is a delta-type robot that puts the product directly into the box or packaging machine at a rate of 400 pieces per minute. Specially designed pliers can pick up all kinds of objects. This technology can adapt to changing production flow. The company also provides customers with a wide range of technical and maintenance training, which is important for the review of robotics technology.

Admittedly, robotics has brought us many benefits, including faster production speed, more accuracy, higher efficiency, and greater output. Just as the introduction of new technologies has certain risks, such as high implementation costs, training personnel, special adjustments, supplier support, maintenance and change procedures. However, we can be sure that the use of technology will eventually bring benefits, and there should be other benefits. For example, robots replace high-risk jobs and employees have a better working environment.