End of line robots. Objective: efficiency

For a Jamaican facility of an Italian beverage multinational, Skilled Group (part of Veneto-based Euroimpianti Spa) has implemented a palletization system that is automated with Comau robots, a solution which has enabled rationalizing and enhancing the efficiency of production processes.

In order to enhance end of line productivity with a palletization system specially designed for a well-known Italian multinational operating in the beverage industry, Skilled Group of Schio (VI) made use of Comau anthropomorphic robots, enabling it to completely automate the existing palletization lines at the customer’s Jamaica facility.
In the words of Patrizio Trecco, technical director and majority shareholder of Euroimpianti Spa and head of Skilled Group: «The palletization system which we have created has enabled completely automated sorting and positioning, on one or multiple pallets, of various box types for carrying rum and a variety of other beverages. The process, organized on five different palletization lines, involves the use of four Comau PAL 180 robots, which carry out all the end of line operations necessary in order to pick and place selected products on pallets before they are wrapped and put in storage, with the objective of rationalizing the facility and enhancing its productivity».

Robotized palletization: high productivity and more rational processes
The customer needed to enhance the operational capacity of end of line processes at a rum production facility in Jamaica that needs to operate non-stop 24/7.
«We built five high capacity palletization lines right in the product packaging area to place various boxes containing bottles of locally produced rum on various pallets», explains Trecco. In order to enhance process efficiency, each line is completely automated using Comau PAL 180 robots. Each robot performs certain palletization operations on a dedicated line, while just one of the four Comau PAL 180 robots operates on two lines simultaneously, satisfying the customer’s express requirement to activate one of the five production lines on an as-needed basis during certain times of year, on holidays or for promotions». In addition to enhancing the speed, output and efficiency of the Jamaican facility’s production lines, the automated palletization system has also made it possible to rationalize its productivity.

The operations now performed by the PAL 180 robots were formerly done manually by at least two operators for every line, working on rotating 7-hour shifts. That’s thirty people tasked with often burdensome work that can now be executed safely and quickly by anthropomorphic robots. Now only highly qualified personnel are employed to program the robots and carry out maintenance work.

A robot adapted for streamlined palletization The process is simple: each end of line Comau PAL 180 robot accurately sorts the boxes containing rum and beverages of varying shape and size. According to product type, each box is precisely positioned on the pallet by the robot. The Comau robots use special clamps that grip the box not only on the sides, but also from below using a special comb structure. This guarantees that boxes never slide out of the robotized arm’s grip as they are moved. Comau PAL 180 3.1 robots are anthropomorphic, fast and robust, specifically designed for palletization, manipulation and high speed operations. These innovative 4-axis machines feature impressive performance, such as a maximum wrist payload of 180 kg, and an additional 25 kg on the forearm. Their maximum horizontal reach is 3100 mm, and they guarantee 0.10 mm repeatability. They can be installed on the ground or ceiling, enabling the most efficient use of the available work space. The mechanics of this Comau series, equipped with dedicated tools (built and designed by Skilled Group) integrate perfectly with the solution developed for the beverage producer. «We have worked for many years with Comau - stresses Patrizio Trecco, technical director and majority shareholder of Euroimpianti Spa and head of Skilled Group - which supplies the robot mechanics for us to develop integrated custom applications for our customers in many different sectors, from food to automotive, to chemicals and pharmaceuticals. Skilled integrated robots are suitable in every way for beverage palletization operations. Programed to function at accelerating or decelerating speed for perfectly synched motion, they minimize potential damage to the products to be palletized at the end of line, making them an excellent option wherever particularly accurate load motion is required». Comau PAL 180 robots use special clamps that hold in place the boxes not only on the sides but from below, using a special comb structure that prevents them from dropping while in motion. Anthropomorphic Comau PAL 180 robots are fast and robust, specially designed for palletization, pick & place and high speed processes. According to product type, software developed by Euroimpianti - Skilled Group enables the robots to position the boxes on the pallets with a high degree of precision.