In some high-speed applications a robot can be used to handle the packaging materials themselves. The robot accepts cases of flat cartons as shown below.

The robot then loads the infeed magazine of the cartoning machine in order to ensure uninterrupted operation of the cartoning process.

With each cycle in a full layer depalletizing application, a 4-axis M-410iB robot acquires a full layer of cans with a tier sheet on top. After the layer of cans is separated from the magnetic tooling, a vacuum system retains the tier sheet until it’s deposited on an outgoing stack for reuse.

When the pallet is completely empty, the robot also transfers the empty pallet to an outgoing stack. Then a new load can be introduced into the system.

In a glass palletizing system, a wide variety of bottle sizes is accepted. It also handles bottles in bulk as well as corrugated shippers. The R-2000iB layer-forming robot performs automatic tool change to switch between bulk and shippers, while the M-410iB layer-palletizing robot requires no changeover. The M-410iB palletizes the product, handles layer separator boards and the top frame on each pallet load. The same system can be used for plastic bottles as well. Perfect loads that minimize product damage are produced by precise alignment of each successive layer on the previous layer.

Casepacking plastic containers is a common robotic application. A variety of robots, gripper types, and system configurations can be applied to provide high speed, production flexibility, and quick changeover. Often a 6-axis robot is used so that the case can be tipped during packing, to take advantage of gravity to help stabilize previously-packed layers of product.

Non-carbonated beverages in the bottles are extremely fragile and can be damaged by conventional palletizing equipment. By handling the products more gently, the robotic system eliminates product damage and enables the customer to achieve their sustainability goals for their products. The robotic system also changes over immediately, delivering high OEE.

This system applies molded plastic handles for large beverage containers.

The robots easily accommodate misalignment of the incoming cases, using offsets from an upstream iRVision camera.

PickPRO was used to prove out the process before any hardware was built.

The robotic system in this paper packaging application greatly simplifies the packaging operation traditionally performed by expensive and expansive hard automation.

Consolidating and combining multiple functions into the robotic stations created an efficient and less expensive system.

This high-speed application for cartoning bars uses the robot not only to pack the cartons, but also to act as the in-process transfer mechanism from the carton erector to the outfeed conveyor. Note the gripper motion to change the product spacing while transferring between the bar wrapper outfeed and the cartons.

A 4-axis M-420iA robot uses a high throughput vacuum gripper with adjustable pitch to pack bars and transfers cartons to a pallet.

In the following example, flour is stacked in corrugated shipping gaylords, or corrugated fiberboard bulk boxes, using a 4–axis M-420iA robot with a vacuum gripper in a compact, high-speed system.

Flour bags are then collated and stacked in the boxes in a 1 infeed, 2 pallet system. This system solves the notoriously common ergonomics issue of reaching into deep, high-walled containers found in many manufacturing settings.

The flexible casepacking system accommodates a variety of products including products in cartons, sleeves, open-top case, etc. Multiple processes can be performed in one workcell by the same robot maximizing throughput and minimizing floor space. The center robot performs multiple functions such as delivering empty cases to the casepacking robots, handling full cases of various types, and also handling and applying adhesive to the lid of the open-top case.

In this workcell, a 6–axis M-16iB robot and a 4–axis M-420iA robot are used.

By using vision , the robots in these next few examples emulate hand-eye coordination to deliver the production flexibility to process multiple product types, while changeover, if required at all, is limited to the robot grippers. In this system, the same robots and identical infeed conveyor accommodate small rounds, large rounds and breadsticks. Note the robots casepack the product as well as the layer-separator sheets with each cycle.

Sophisticated software coordinates the activities of the 8 robots to process the incoming product flow and differing product sizes. This advanced function is called “load balancing.” Product changeover is accomplished with ease as the robot quickly changes from picking up six frozen dough items to two.

Rice waffles are transferred at high speed to downstackers which then feed baggers for the waffle stacks. Vision on a 6-axis LR Mate 200iC robot is used not only to guide the robots to the waffles for picking, but also to screen out any broken or misshapen waffles as an in-process quality check. Sophisticated PickTool software from FANUC coordinates the activity of the multiple robots to share the workload and process the incoming waffle flow. This advanced function is called “load balancing.”

Bread and rolls shrink significantly from the time when they exit warm from the bakery oven, and then cool on the way to grocery shelves. Robotic systems provide highly flexible pack-pattern options, and apply just the right amount of compression to baked goods to compensate for cooling and shrinkage in order to achieve the optimal shipping density and product quality. By shipping more product in every tray, logistics costs are significantly reduced: fewer tractor trailer trips, reduced storage and replacement cost of in-process baskets, reduced staffing to handle baskets, etc.

This versatile high-speed picking system accepts frozen specialty sandwiches from the upstream freezer and transfers them to the infeed of up to 3 flow-wrappers.

Highly advanced PickTool software coordinates the activity of the 18 robots in the line. In addition to accepting a variety of flavors, the system provides tremendous operational flexibility and uptime: under normal operation, 6 robots serve each of 3 flow-wrapper infeeds, but if any flow-wrapper experiences downtime, the speed of the remaining 2 flow-wrappers is increased and 9 robots serve each infeed – all automatically!

In this example, a robot is used to transfer muffins from baking pans to the retail “clamshell” package. Up to 48 muffins are transferred each cycle, using a mechanical fork gripper for reliable handling. Note the gripper changes the product spacing in two dimensions to adjust from the even spacing of the baking pans to the 2x2 arrays used in the retail package.

The robot used as a transfer device resulted in a significant improvement in the system uptime, by replacing a variety of wear components and individual custom actuations with a high reliability, standard robot. Industrial robots commonly achieve a Meat Time Between Failure (MTBF) performance of more than 80,000 hours.

In this example, single-serving bowls of a grain-based breakfast product are presented in lanes to an auxiliary device that inverts alternating bowls. The robot picks a group of bowls that are right-side up, then immediately picks a matching group of upside-down bowls from the auxiliary device. This picking sequence, combined with a collapsing actuation in the robot gripper, nests the tapered bowls into a high-density pack pattern for maximum shipping efficiency. Four cases are packed simultaneously to achieve production rates of more than 300 per minute.

This method outperforms conventional alternatives with its lower capital cost, higher reliability and maintainability.

In another single portion cup casepacking application, that uses an M-420iA and an M-421iA robot, single-serve portion and condiment cups are shown. Initially, a conveyor system is used to present products to the robot, while an auxiliary device handles layer separator sheets. The robot then picks directly from the indexing table of the filler (machine), and handles layer separators as well.

Finally, the robot picks directly from the filler and then passes the products past an inkjet-printer to apply a date code “on the fly”. In all applications, the robot gripper adjusts the spacing from the infeed to fit within the case inside dimensions.

In the following example, a food-grade 6–axis M-430iA robot loads empty coffee packets to a filling machine. If you look closely, a small tab is visible on each packet. This is the filling tab and it is randomly oriented on the infeed conveyor. FANUC Robotics' iRVision is used for guidance and to determine the proper orientation of the fill tab so that the filling process proceeds smoothly.

In this example, robots are used to casepack single-serving bags. Advanced application software is used to coordinate the picking and placing activities of all three robots, including tracking the status of the fill level of the corrugated cases on the outfeed conveyor. Vision guidance combined with vacuum grippers allows for simple conveyance, fast changeover, and high reliability.

Bags not cut into single-serving bags appropriately are skipped and not stacked, as shown below.

In another similar application, a unique multi-part mechanical gripper and robot motion is used to create the packing pattern within the case.

With a simple gripper changeover, the system accommodates 5 lb. and 20 oz. bags, and packs to plain corrugated cases as well as cases lined with poly bags.

In another example, two different sizes of bags of soup are casepacked in the same system. A unique feature of this system is the innovative gripper that mimics the pinching motion of the human hand to pick fluid bags.

This system is complemented by easy changeover to a vacuum system that handles frozen bags securely.

In this example, two robots are used to achieve high throughput rates in a bag palletizing application. Note that the robots are installed at two different elevations to optimize the performance of one robot for the lower half of the load, and the other robot for the upper half. Sophisticated software prevents collisions of the two robots during operation.

Many products in addition to food are transported in bags, such as pet food, gardening products, construction materials, powdered ingredients, etc.

Many customers struggle with ergonomics issues when placing human operators in environmentally dangerous work atmospheres. In this case, a nasty ergonomics problem has been solved. Note the back brace and respirator on the operator shown below.

In this installation the robot is used instead, with minimal impact on floor space while providing a significant improvement in productivity and worker safety.

In this operation, the bags are placed on a fill nozzle to be filled.

After the bags are filled, a multi-function gripper and an M-710iB robot is used to palletize each bag efficiently.

In one application example, lettuce heads are first dropped randomly on a conveyor.

After the lettuce heads are singulated, a vision system measures the shape and form of the lettuce and determines where to cut the root.

The FANUC LR Mate 200iB robot helps to perform a second check on the lettuce head to determine its size. If it passes the final test, the lettuce head is then placed successfully into plastic trays.

This system highlights the benefits of robotics compared to a manual operation. With manual casepacking, handling of eggs can vary widely across individual employees and over the course of a shift as fatigue sets in. Users of this automated casepacking system all report significant yield improvements, with fewer cracked eggs. Higher employee morale and customer satisfaction have also been key benefits of the systems.

This application uses 6-axis R-2000iB robot, 6-axis M-710iC robot and a 4-axis M-410iB robot to rack and unrack balls of Edam cheese to be stored for the aging process.

High speed multi-part vacuum and mechanical grippers are used to transfer them to the infeed of a coating machine where they get their distinctive red paraffin wax coating. Quick product changeovers are accomplished to accept three different product diameters/weights.

The cheeses continue through wrapping and labeling processes to a robotic casepacking system. After the cases are closed they are conveyed to the robotic palletizing operation.

In another cheese packaging application, cheese packages are slit and separated into individual products which need to be labeled with a date code. A vision-guided M-430iA robot identifies the packages after the slitting operation and transfers them with proper orientation to a conveyor feeding the downstream labeling machine. The USDA-accepted M-430iA is “clean sheet” robot design for food applications. It is inspectable and cleanable, and resistant to chemical attack, providing an excellent platform for sanitary food-processing robotic applications.

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