Project Feature:
☑Customization □Flexibility □Integration □Empowerment □Cost-Efficiency Optimization
Project Background & Requirements:
A high‑volume dairy plant in Eastern Europe needed to eliminate manual handling at the cold‑chain end of a single‑format Aseptic Carton “Flex Base” line running ≈116 packs min‑¹ (≈11 pallets h‑¹). The brief required a compact, fully automatic palletising cell—including stretch‑wrapping—that could be dropped into the existing footprint without disrupting upstream production.
▶ Requirements (extract)
Passport speed of the packaging line = 116 single packs/min;
Weight of single pack = 1090 g;
Number of single packs in a group pack = 12 pcs; Number of group packages in a pallet: 52pcs.
The average speed of product exit from the line coincides with the rated speed of the
filling line and is 9,6 group packs/min, or 11,15 pallets/hour;
The instantaneous speed of product exit from the line exceeds the rated speed of the filling line and can be adjusted within the range from 116 to 118 group packs/min, or from 11,15 to 11,34 pallets/hour.
The products exit the line in the form of 1 group package; Group packages exit the line with the long side first; Cardboard interlayer – required.
Project Solution:
▶ System Components
Depalletizer (automatically feeds empty pallets)
Case organizer & conveyors (chain + roller)
Robotic palletizer (KUKA 6-axis, 70kg)
2-in-1 gripper: carton grabbing + sheet suction
Stretch wrapper (rotary type)
Safety fencing with interlocked doors
Electrical system (PLC + HMI touchscreen)
▶ Working Process
Depalletizer places pallet → robot places interlayer sheet
Picks 2 cases at a time (1 for the last box), palletizes in staggered layers
Builds 4 layers → transfers stack to stretch wrapper
After wrapping, rotates 90°, moves to exit, forklift removes the stack
Project Outcome:
Our proposal won the tender ahead of multiple international competitors. The line was under production.
It is purpose‑built to match the plant’s exact pit size, line speed and layout—using a dual‑mode gripper and an ultra‑compact footprint.
