Dual-Axis Case Packing Robots: Precision in Case Packing and Palletising
Created on 06.08
The manufacturers want to increase their production rate. They have to reduce costs and ensure safety for their products. This is where automation comes into play. Automated Dual-Axis Case Packing Robots are a breakthrough in this domain. The way we see case packing and palletising changes greatly because of these robots. Why choose them? Because they do better than old-fashioned single-axis robots.
Market Dynamics: The Ascendancy of Robotic Case Packing
The industrial robotics market is growing fast. Industrial robots will grow 10.5% yearly from 2023 to 2028 (IFR World Robotics Report 2023). Packaging automation is key here. The global packaging robots industry is estimated to touch $8.5 billion by 2029 (Mordor Intelligence, 2024).
These gains come from nowhere. Inspection of factories reveals that there are issues with bottlenecks, such as case packing and palletising, that reduce the efficiency of operations. These challenges are solved by using dual-axis robots. Furthermore, 72% of manufacturers have plans for automation.
Driving Automation Adoption
Demand for flexible automation is high. Production lines change often. Machines must adapt to many products without big retooling. This means more robots doing complex tasks. Twin-axis systems are popular. They are smarter, not just faster.
Sector-Specific Impact
Food, beverage, logistics, and home chemicals use case packing automation a lot. They need fast, clean, and exact handling of many products. It also consists of bags and bottles. Bagged and bottled products greatly benefit from twin-axis robots because their adaptability renders them indispensable.
Performance Measures: Twin Axis Robots' Performance Levels
The capabilities of twin-axis robots can be measured by high levels of performance and accuracy. They can work simultaneously along two axes. It cuts cycle times and boosts throughput. See how these systems stack up.
Optimising Throughput and Speed
Throughput is key. Twin-axis case packers can hit 30-45 cycles per minute. Speed depends on product weight and case type. Faster speed means more products. A game-changer for high-volume lines.
Precision and Flexibility
Accurate case packing automation stops product damage. It also makes stable pallets. The robots have a repeatability of ±0.05mm. This makes sure that there is consistency in placing the products and robust packing of the pallets. The robots can also move to various products. This is essential in diverse manufacturing.
Metric | Automatic Twin-axis Casepacking Robots | Single-Axis Casepackers (Typical) |
Operational Speed (cycles/min) | 30 - 45 | 15 - 25 |
Payload Capacity (kg) | 25 - 50 | 15 - 30 |
Repeatability (mm) | ±0.05 | ±0.1 - ±0.2 |
Footprint (m²) | 4 - 6 | 3 - 5 (less flexible) |
Axis of Movement | 2 (X, Z) | 1 (Z or X) |
Integration Complexity | Moderate (Customized End-of-Line Integration recommended) | Low-Moderate |
Global Packaging Standards Compliance
Automation must adhere to strict standards. These standards include global and local standards. Adhering to these standards ensures safety, quality, and market entry. Two-axis robots comply with these standards.
Robot Safety
There are several safety requirements that need to be followed by an industrial robot, as in our case. ISO 10218-1:2011 outlines the robot requirements. Manufacturers can also review current guidance on industrial robot safety standards when evaluating robotic case packing and palletising systems. ISO 13849 deals with machine safety. Manufacturers aim to obtain the CE marking in order to prove their compliance with EU standards. Working with experienced providers of robotic packaging automation solutions helps manufacturers ensure compliance, improve line efficiency, and achieve long-term operational reliability. It is imperative.
Handling Procedures
The safety of goods is equally important. FDA regulations and GMP are mandatory for all food and beverages. The packaging process must prevent contamination from either bottles or bags. ASTM standards provide product protection. We assist our customers in customised end-of-line integration.
Quality Management Systems
Makers using these robots get good quality management. ISO 9001 certification shows a commitment to quality. This covers all production steps. It ensures that we have high-quality palletising and heavy materials systems. It promotes trust.
Economic Incentives and ROI for Case Packing Robots
Case packing robots require certain economic incentives to be justified. ROIs should be considered. The robot that we will use, the Twin-axis Casepacker, will lower our labour costs. It will increase efficiency and effectiveness. These robots do not only represent expenses but also smart investments.
Calculating Payback Periods
Businesses usually see ROI in 18-36 months. This depends on system complexity and labour costs (FANUC Robotics). One twin-axis robot can replace 2-3 workers per shift. This saves big on labour each year. It speeds up ROI. You will see results fast.
Energy Efficiency Gains
Modern robots save energy. Twin-axis robots use better motion paths. High-efficiency servo motors cut power use. They use less power than older systems. A study shows case packing automation can cut energy costs by 10-15% (Schneider Electric). These savings grow over time. Other than the savings, traceability can also play an important role. Barcodes minimize any possibility of mistakes and recalls, adding to profitability. Collaborative palletizing robots can also be considered. They guarantee seamless material handling.
Key Metrics for Making Your End-of-Line Operations Future-Ready
Metrics play an important role in maximizing benefits from your case packing system automation efforts. Key performance indicators will enable you to enhance efficiency of your twin-axis robots and entire end-of-line systems.
Efficiency Metrics
- Overall Equipment Effectiveness (OEE): The OEE metric measures equipment availability, equipment performance, and quality. It is essential for automatic production lines to be at least 85% OEE. Testing frequently helps reveal problems that will help maximize efficiency in bagging or bottling production lines.
- Throughput Rate: Determine the amount of goods packed per minute or per hour. Measure whether or not you have reached your own standards. The twin-axis robot should complete 30 to 45 cycles per minute.
- Changeover Time: Observe the changeover time when it comes to switching between products. Ideally, a custom-made automation process will take less than 15 minutes.
Indicators of Quality and Cost
- Defect Rate: Inspect the packaging to see if there is any defective or wrong packaging. Robots help keep the defect rate below 0.1% and ensure consistent quality.
- Labour Productivity: See how much labor is saved in packaging and palletizing. The robots will make workers more productive doing other work.
- Energy Used Per Unit: See energy used per unit. This is an indicator of energy efficiency. You can see where there is room for savings.
These robots help manufacturers design robust lines. The numbers support that. Concentrate on these indicators. Your automation project will yield dividends. Or, if you are ready to discuss specific needs, reach out to our team for a consultation.
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