CASE STUDIES

Robots jam packed with features

A Toshiba Machine robot from TM Robotics has helped a preserves manufacturer out of the perennial jam of gaining the maximum sales potential from the minimum retail shelf space.

With competition for shelf space always at a premium, a major discount food retailer wanted one of its food suppliers to package four varieties of its jams into a single point of sale tray. However, the preserves company’s existing production line allowed for only 12 jars of the same flavour jam to be packed into each tray.  Not only did its process line require modification, but the need for a flexible automated handling system was identified.

TM Robotics worked with systems integrator EMT and German sales partner K-Robotix to supply a system, which had to be cost-effective, simple to operate and modular in design to enable flexibility.  The resultant robot based system means the preserves maker can now supply jam in mixed lots to meet the discounter’s requirements.

The existing equipment only allowed for one variety of jam at a time, coming direct from the production line, to be placed in the twelve-jar trays.  No straightforward or cost-effective method could be found to change this. The only solution to producing the necessary assortments was, therefore, to carry out the mixing process by adding an extra production stage.

Initially, this extra step was not mechanised, as no suitable equipment appeared to be available to produce the assortments automatically.  Consequently, the work was carried out by hand, one jar at a time. This clearly presented not only a boring task for the packers, but also the risk of repetitive strains and fatigue.

The task of mixing the varieties was outsourced and although this solution met the cost constraints, the jam manufacturer quickly discovered that the services offered by even the best subcontract packagers were unreliable.

Initial research into ways of mechanising the process proved disappointing, as it seemed that the type of machinery required for the task would be complicated, expensive and inflexible. However, it was suggested to the preserves manufacturer that it might be possible to use a standard robotic system to provide a viable solution. 

Acting on this advice, the company sought advice from EMT, a system integrator with broad experience of robotic solutions.  EMT, working together with K-Robotix, and drawing on the technical support of the Toshiba  expert, TM Robotics, analysed the problem.  The conclusion the three companies reached was that a robot solution was not only possible, but that it would meet the cost, flexibility and ease of use needs. 

The approach which was finally adopted for the mixed product pack line was based on the use of simple, cost-effective modular robots.  In essence, it consists of a depalletiser operating in conjunction with a powerful Kawasaki FS 030 palletiser, which has a 30kg loading capacity.

The mixing process is carried out by a horizontal multi-joint Toshiba Machine SR 854 HSP SCARA robot, which was selected for its 850mm reach and enhanced 20kg payload - a capacity much greater than usual for a robot of this size.  The robot picks jars in a programmed sequence from four single-flavour trays and accurately places them in the mixed trays.

The newly developed multifunction system allows for automatic and consistent combinations of the four different products. The robot offers repeatability to ±0.02mm on the X and Y axes and ±0.01mm on the Z-axis ensuring the jars are safely stacked. The system delivers exceptionally smooth, fast motion. Combining this with a highly sophisticated set of control instructions the Robot can be programmed quickly and easily to meet the requirements of virtually any application. 

Automating the process has greatly improved the throughput and reliability of the jam packaging process and the plant can now handle up to 40 trays per minute. As the system features modular construction it is easy to move from place to place if, in the future, the requirements of the application or its location should change.

The SCARA robot is also easy to re-program to cope with operational changes, such as the packing of jars which have different shapes or which are made from materials other than glass.

“It is a brilliant experience to work with a company that has never been involved with robot automation, like the preserves manufacturer in this case,” said Nigel Smith, managing director of TM Robotics. “At the outset, we were working with engineers who were uncertain of their needs. By the end of the project, however, those same engineers were delighted with the results and became firm converts to the technology.”