Case packing is usually one of the most difficult processes in the final stage of the production line. The products have to be gathered, sorted, and packed into the case in an organized manner while the line keeps moving at the set speed. In situations where the products' sizes, types of cases, or packing patterns change, the whole process becomes even more challenging to handle.

For these reasons, automation of case packing is being considered by more companies. The use of robots will help handle the repetitive tasks and make the process more consistent. Nevertheless, choosing the correct technology goes beyond buying a faster robot. It depends on the kind of products, cases, and requirements of the production process.

There are several considerations that should be taken into account before choosing an appropriate technology.

In the beginning, it is necessary to precisely determine what will be handled by the system. The weight of the products, their size, shape, packaging material, and surface characteristics may have an impact on how the products will be handled.

It is necessary to consider the format of the case as well. The size of the case, its opening, interior, and packing pattern will determine the movements of the robot and the configuration of tooling. The products that have a similar appearance may need to be handled in different ways due to differences in weight and packaging.

Thus, a complete list of the products and cases will provide much more precise information for the supplier of the automation system.

Robot speed is an important consideration in automation but does not give a complete picture.

A case packing line includes product infeed, product positioning, picking, case handling, packing, and downstream processes. If products do not arrive at the robot consistently, or another machine operates more slowly, the robot cannot compensate for the bottleneck by itself.

For this reason, manufacturers should evaluate the complete process instead of comparing robot cycle times alone. The goal should be stable line performance rather than simply achieving the highest possible robot speed.

Manufacturers evaluating a complete case packing automation solution should therefore look at how the robotic cell works together with the rest of the end-of-line process, rather than treating the robot as a standalone machine.

The end-of-arm tooling is another important element in the process of case packaging automation. The gripper should keep products stable while moving them at the necessary speed and positioning them inside the package.

There may be a variety of gripping solutions for different products. Vacuum gripping can be applied to those products that have suitable surfaces for that technology, while special mechanical grippers may be more efficient for other cases.

It is also important that the gripper should facilitate the necessary packaging pattern. In the case when there is a need to package various SKUs, flexible tooling design may become crucial.

For manufacturers handling bottles, bags, boxes, or other packaged products, the choice of robot and gripper should be evaluated together. For example, an automatic twin-axis case packing robot can be configured with different gripping approaches according to the product and packing requirements.

There are very few cases where the same item is produced on a single line. The introduction of new SKUs, seasonal production, varying sizes of packaging, or changing customer needs are some reasons for this.

Hence, it is vital to understand the changeover procedure before finalizing your choice of machinery. Ask about the changeover process for different products and packaging, the method for tooling changeovers, and whether any adjustments can be done by the operator without going through many processes.

A case packer machine, which only caters to current production, can become a limitation in the future.

Automated case packing equipment is almost always an integrated component of the larger manufacturing process system. In order to function correctly, the robot will need to be compatible with the rest of the systems, such as conveyors, product infeed, case handling systems, controls, and safety components.

Space and layout planning is another important consideration. Factors such as available floor space, conveyor direction, operator access, maintenance area, and material handling could influence the design.

Compatibility does not only include connecting equipment together. Overall, the entire line should be designed with efficient product flow and reasonable operator/maintenance access in mind.

Safety must be taken into account when the system is being designed, not afterwards.

The robot cell, conveyor system, access points, and other moving equipment that moves must be taken into consideration within the context of the whole system. The proper safety measures must then be included within the design as per the appropriate standards for the installation.

Access is also important. There may be situations where it becomes necessary for workers to load material, adjust the machine, check parts, or deal with a disruption of some sort.

The process does not stop after the robot has been installed. The ongoing reliability of the equipment needs to rely on inspection, maintenance, and training.

The robot manufacturer needs to know what parts need ongoing attention, the maintenance of tooling, and the consequences of a common problem. Availability of spare parts and support services may also become important factors for production situations where downtime is expensive. Recent PMMI research on robotics in packaging and processing also highlights reliability, uptime, integration, maintenance, and post-installation support as important considerations when manufacturers evaluate packaging robotics.

A machine that can be easily understood and maintained by the production team may be more useful than one requiring specialized help for every modification.

No one specification guarantees success or failure of a case packing automation project.

The product's properties, case formats, packaging configurations, throughput demands, grippers, changeovers, line integration, safety, maintenance, and future SKUs all have to be taken into account.

The best strategy for a manufacturer is to establish the production requirements and pick a robotic case packing solution accordingly. This way, it will be easier to avoid picking a fancy system that doesn't fit into the manufacturing facility.

When an automation solution is based on the entire packing process, it turns into an effective investment instead of just a replacement for manual operations.