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Robotic Case Packing & Palletizing of Rolls

The Client & Objective

The world's largest manufacturer of protective packaging materials presented MMCI with a new task of automating a roll packing and palletizing process in an effort to not only address labor issues but to make the system safer, faster, more reliable and smarter.

Roll Palletizer

For MMCI, automating the palletizing process seemed relatively standard, but automating the roll handling and case packing process was going to require some very creative engineering due to a number of issues:

Multiple Roll Sizes
2 different lengths in two different diameters
Large and Heavy
The larger rolls weighed up to 65 pounds and were difficult to handle
Complex Process
Required two people to manipulate the rolls and place them in the boxes
Damage
Rolls and boxes were often damaged in the process

The Solution

Our engineering team started by designing a system using robotics and other automated equipment to replace all of the heavy lifting and manual labor being performed by workers.

  • Infeed process with zone accumulation conveyors
  • Robotic palletizing arm that also dispensed slip sheets
  • Dual shuttle system for outbound pallets
  • Automated pallet dispenser

The key element of the project was the customized, multi-tasking robot engineered to:

Multi-Tasking Robot - End-of-Arm-Tooling

Use suction cups on hinged tooling to grab and erect case

End-of-Arm Tooling Suction Cups

Orient case and run through sealing machine

End-of-Arm Tooling Orient the Case

Grab, manipulate and load the roll into the case

End-of-Arm Tooling Loading the Roll into the Case

To accomplish these three tasks, we custom fabricated the EOAT and outfitted it with a customized ID gripper that secured each roll and placed it gently placed into the case while leaving the outer layer of film untouched.

To make the system smarter, we outfitted it with a scanner and print-and-apply labeler to capture important information and document each package.

Roll Data Scanner

Collect Data from the Roll

The cell features a scanner that reads the laser etched barcodes for quality control and tracking purposes.

Case Print-and-Apply Labelers

Apply a Label to the Case

Cases from both robotic case packers are conveyed through automatic print-and-apply labelers and into the robotic palletization cell.

Robotic Cell

By automating the case packing and palletizing processes, MMCI was not only able to help our client address its primary challenge of finding labor for this physically demanding work, but it also increased productivity, enhanced quality and improved product tracking.

How Can We Help?

At any stage of your automation project, we can help. Call us at 314-438-3300 or fill out the form below.