Three robotic packing cells developed by Motoman Robotics and supplied as turnkey systems to Wrexham, UK-based Calypso Soft Drinks have enabled significant improvements in efficiency. In one case, introduction of an SV-3 robot for placement of 85ml cuplet drinks into outer boxes has allowed line speed to be increased by 25 per cent. In another, the cell has succeeded in automating the palletisation of 56 different product and pack size combinations onto shipping pallets.
Calypso decided to automate the palletising function on four lines producing Tetra packed drinks. This is quite a complex task as the system has to be capable of coping with trays comprising either 24 or 27 packs with further variation occasioned by the use of 200ml and 250ml packs in addition to differences in the flavour of the actual product. In all there are 56 pack variations that demand three different pallet stacking patterns.
The aims of the robot packing project were well defined from the start. One cell would be required to place the six 200ml packs and cuplets into cartons as they came off the filling line. Flexibility was needed to pack 200ml six-packs at a density of four packs per box, or individual cuplets at a density of five layers of 20 per box. Specified packing time was four seconds per box for the six-packs. An additional requirement for the cuplets was the insertion of a cardboard separator between each of five layers; around 20 seconds/box is allowed on this product. A second cell on the same line was required to stack the cartons from the cup line onto pallets, with a maximum case weight of 12kg for the cuplet boxes.
As installed, the latter system comprises a pair of Motoman SV-3 robots for box filling.
Once a pallet load is completed, the pallet is moved away from the load area on a powered roller conveyor. The robot then picks an empty pallet from an integrated pallet stacker using hook-type lifters built into the box handling attachment. The new pallet is placed onto the load area.
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Motoman Robotec is based in Allershausen, Germany. www.motoman.eu
