Robotic Case Packing & Palletizing Automation System

MWES provided our customer with a robotically automated system that utilizes a 4-axis delta robot, an automatic case former with inline flange sealer, a case labeling station, a case weight check station and an industrial 6-axis palletizing robot with a vacuum cup EOAT. The various production stages are connected via multiple USDA-rated conveyors. The operator utilizes the RSView HMI to select a production recipe and the recipe data is transferred in a one-way fashion from the Recipe Manager Database. 

The process begins at the HMI where the operator selects a production recipe and loads a trolley into the trolley handling bay. The system starts and the case-forming machine takes flattened case blanks, folds the bottom flaps and glues them into place. The case forming conveyor transfers the formed cases onto the case packing conveyor. The formed cases pass through a sensor that tracks the case’s placement on the conveyor. The bags are rotated 90 degrees and enter the case packing machine in a staggered fashion on a separate conveyor. The case packing robot tracks the placement of the bags on the infeed conveyor. Once the bag enters the bag picking area the robot picks a bag one at a time and places it inside the corresponding case.

After a case has been filled, it indexes to the automatic weight checking station for a final weight check to ensure product accuracy. If the case’s weight aligns with the weight requirements the case is transferred to the case closing and sealing station. The adhesive is applied to the case flaps and the flaps are then folded down. If the case fails the weight check, the flaps are folded down without adhesive so that it is easier for the case to be manually reworked by the system operator and transferred to the reject station. The sealed cases are transferred to the labelling station where required product information is placed on the case.

Once the labeled cases are complete they are indexed to the palleting robot. The robot picks individual cases and stacks them on a wheeled trolley. Once the trolley is full, the operator removes the trolley from the loading station and places an empty trolley in its place.