Espresso manufacturing is rising worldwide.
From roasted beans to capsules and pods, producers are rising output to fulfill rising demand. Capsule codecs corresponding to Dolce Gusto® and different single-serve methods proceed to increase in each retail and meals service.
However whereas packaging expertise has advanced rapidly, many espresso crops nonetheless depend on guide palletizing on the finish of the road.
That’s changing into more and more tough to maintain.
Operators are tougher to rent. Labor prices are rising. And palletizing stays one of the crucial repetitive jobs on the manufacturing ground.
Consequently, many espresso producers at the moment are automating palletizing to stabilize operations and scale back labor stress.
Just lately, a serious European espresso producer confronted precisely this case.
Their purpose was easy: take away guide palletizing from their capsule packaging traces with out creating a fancy robotics mission.
The everyday espresso palletizing problem
The producer was working two espresso capsule packaging traces producing instances of pods prepared for cargo.
On the finish of every line, completed instances have been palletized manually by operators working throughout three shifts.
Their setup seemed like this:
- 2 packaging traces
- 3 manufacturing shifts
- 1 palletizing operator per line
- Steady pallet constructing with interlayers
Every line required a devoted operator to stack instances onto pallets all through the shift.
Over time, the challenges grew to become clear.
Labor prices add up rapidly
With guide palletizing operating throughout three shifts, the corporate was spending roughly:
€180,000 per yr in labor prices only for palletizing.
And that price continued to extend as wages rose.
Staffing was tough
Like many meals producers, the corporate struggled to maintain palletizing roles stuffed.
The job is bodily repetitive:
- Lifting instances
- Repeating the identical movement a whole bunch of occasions per hour
- Working repeatedly on the finish of the manufacturing line
These positions typically expertise excessive turnover and absenteeism, creating further stress on manufacturing groups.
Palletizing can grow to be a bottleneck
When palletizing slows down, the complete manufacturing line will be affected.
If instances accumulate on the finish of the road, operators should intervene to clear the backlog, which might gradual manufacturing or disrupt workflows.
For this espresso producer, guide palletizing was changing into each a labor problem and an operational threat.
Not each product is straightforward to automate.
However espresso instances are sometimes a wonderful match for collaborative robotic palletizing.
Espresso producers sometimes share a number of traits that simplify palletizing automation.
Constant case sizes
Espresso capsules and pods are often packed into standardized transport instances, making them predictable for robotic dealing with.
Predictable pallet patterns
Most espresso crops use repeatable pallet configurations optimized for transport and warehouse storage.
Robotic palletizing methods can simply reproduce these pallet patterns.
Average decide charges
Many espresso packaging traces function at average palletizing speeds, sometimes between 4 and eight picks per minute.
These speeds are nicely throughout the capabilities of collaborative palletizing methods.
Steady merchandise
Espresso capsules packaged in corrugated instances are sometimes light-weight and secure, decreasing complexity for robotic gripping and stacking.
Collectively, these traits make espresso palletizing a powerful candidate for cobot automation.
For this producer, the palletizing necessities have been clear:
- Decide price: as much as 6 picks per minute
- Pallet peak: as much as ~2.4 meters
- Interlayer placement required
- Two impartial packaging traces
These circumstances made the appliance a powerful match for standardized cobot palletizing somewhat than a customized robotic mission.
As a substitute of designing a fancy robotic system, the corporate might deploy pre-engineered palletizing cells designed particularly for end-of-line automation.
The producer put in two collaborative palletizing cells, one devoted to every packaging line.
Every cell handles the whole palletizing course of:
- Selecting completed espresso instances from the road
- Constructing the pallet sample mechanically
- Putting interlayers between pallet layers
- Finishing full pallets prepared for cargo
As a result of the system is constructed round a collaborative robotic (cobot), it could function inside typical manufacturing environments with out the complexity typically related to conventional industrial robotics.
Operators can proceed working close by whereas the palletizing course of runs mechanically.
Quicker deployment
One other benefit of standardized cobot palletizing methods is easier deployment.
Conventional robotic palletizing initiatives typically require:
- Customized engineering
- Lengthy integration timelines
- Intensive security infrastructure
Collaborative palletizing methods are designed particularly for palletizing, which might considerably scale back set up and commissioning time.
For a lot of meals producers, this makes automation a lot sooner and simpler to implement.
After automation, the producer was capable of take away guide palletizing from each packaging traces.
The cobot palletizing cells now deal with the repetitive stacking work mechanically.
This created a number of instant advantages.
Operators reassigned to higher-value duties
As a substitute of stacking instances all shift, operators might give attention to:
- Line supervision
- High quality management
- Materials dealing with and logistics
This allowed the plant to use its workforce extra successfully.
Improved end-of-line consistency
Automated palletizing ensures pallets are constructed persistently and precisely, enhancing stability throughout transport and simplifying warehouse dealing with.
Decreased repetitive work
Palletizing includes 1000’s of repetitive lifting motions per shift.
Automation helps scale back repetitive pressure duties, enhancing ergonomics for employees.
The economics of the mission have been easy.
Guide palletizing throughout the 2 traces price roughly:
€180,000 per yr in labor.
By automating the palletizing course of, the producer eradicated most of that recurring labor price.
The outcome was clear:
Payback in lower than 12 months.
For a lot of meals producers, palletizing automation delivers one of many quickest returns on funding within the plant, particularly when labor shortages and rising wages are thought of.
Many espresso producers assume palletizing automation requires complicated robotics integration.
However many purposes are easier to automate than anticipated.
In case your manufacturing line consists of:
- Average palletizing speeds
- Constant case sizes
- Normal pallet patterns
…it might already be a powerful candidate for cobot palletizing automation.
Curious in case your utility is an effective match?
Use Robotiq’s Palletizing Match Software to rapidly assess whether or not cobot palletizing is sensible on your operation and what a sensible deployment might appear to be on your facility.
