Carton automatic loading

The problem

In the food industry, as well as in manufacturing, at the end of the production process, there is a need to insert and package products into cartons for distribution.

An Italian coffee company has asked us to optimize the loading and packaging phase of coffee bean bags into transport boxes.

Loading the flat cartons onto the packer machine is a tiring, repetitive, and completely manual task, despite its low added value.

Operators assigned to this task could be allocated to more important and strategic operations, instead of engaging in exhausting work.

The solution

By integrating sensors and collaborative robotics solutions, we have developed a system capable of automatically loading cartons onto the packaging line, independently managing any carton format loaded on a pallet (with different configurable types).
Specifically, the system is able to:

1. Check the correct positioning of the pallet.
2. Center the stack of cartons.
   This operation determines the position of the carton stack and allows setting reference variables for the entire pallet.
3. Lift and align the cartons.
   The number of lifted cartons is programmed based on the weight of the carton and the arm's load capacity.
4. Move and compact the cartons.
   Once lifted, the block of cartons is placed on the loading platform and compacted laterally and frontally.
5. Verify and correct the grip in the presence of deformed cartons.

The automatic carton supply system we developed ensures accurate quality control and efficient handling of carton loads. By optimizing the packaging processes, it enables a smoother workflow and overall improved productivity.

The innovation

To effectively respond to the typical variables of a packaging line (positions, quantities, weights, and carton formats), our Research and Development laboratory has designed and implemented a gripper capable of adapting to different situations without the need for manual intervention to replace the manipulator or reprogram the system.