Case packing plays an important role in the final assembly process for manufacturers working with canned products. The job of the case packer is to receive cans systematically, arrange them in the required arrangement, and then pack them in the cases without disturbing the production process.

Productivity issues do not necessarily resolve when one increases the speed of robots. The factors that can affect the performance of a case packing system include product infeed, grouping, gripping, case quality, changeover, and many others.

In order to optimize a can case packer system, it is critical to first understand the products and cases that need to be packed in the system.

The key considerations are

The above criteria will dictate how the products should be grouped, picked, and loaded in cases and will help in determining the correct gripper for the job.

The case packer will only function reliably when the cans are brought to a predictable location.

Prior to reaching the robot, the infeed mechanism may have to manage accumulation, spacing, alignment, and grouping of the product. If the product flow is not steady, then the packing cycle will get disrupted despite the robot functioning properly.

Therefore, the manufacturers must consider the following factors:

Stability of the infeed makes the case packing system work consistently.

For robotic case packing, the grouping and picking of cans are factors that have an effect on packing stability.

The gripper must be able to pick up the number of cans needed securely while positioning them inside the case in the proper configuration. The most suitable technique of gripping will depend on can style, product arrangement, case arrangement, and handling needs.

In selecting the robotic case packing system, the manufacturer must take note if the gripper is capable of:

For robotic case packing, the grouping and picking of cans are factors that have an effect on packing stability. A twin-axis case packing robot can be configured with different gripping solutions according to the product format and packing requirements.

Sometimes, the packing problem isn’t necessarily with the robot.

It’s possible for case quality and positioning to have an effect on the loading process. Poor-quality or incorrectly placed cases can lead to problems despite a well-configured packing system.

It would be best for the manufacturer to look into the case itself first before altering the robot program and gripper.

Case packing needs to be seen as part of the full production process. For manufacturers planning a broader automation upgrade, robotic case packing and end-of-line solutions can help connect product feeding, conveying, case packing, and downstream handling within one production flow.

In an automated end-of-line process, the processes could include feeding of products, conveyance, case packing, palletizing, and conveyance of the completed product. When any of these processes cannot keep up with each other, speeding up the case packer itself might not help production in general.

This is why having an integrated approach could be beneficial when improving the production process.

In the case of case packing, for instance, it would need to be coordinated with:

This would help manufacturers determine what causes their production stoppages.

There are many instances where manufacturers will have to process different products or case types on the same production line.

This means that when assessing case packer equipment, the manufacturer must assess not just what is needed currently but how easy it will be to change formats.

Manufacturers will know what parts of the equipment can be changed in a changeover, including:

This does not mean that every conceivable format needs to be made by the equipment. It means the equipment must be flexible enough for the products being used.

Maintenance is crucial in ensuring the performance of case packing remains constant.

Grippers, sensors, conveyors, servo components, guides, and pneumatic components should be checked in accordance with the maintenance needs of the equipment.

Operators should be mindful of recurring problems and not just reset the machine every time there is a problem. Consistent errors in picking, product alignment, or case packing could be an indication of the need for a component to be adjusted or replaced. When making equipment adjustments or modifications, manufacturers should also consider machinery risk assessment principles outlined in ISO 12100.

Nominal speed of a case packer is not an indicator of everything.

Also, manufacturers must look at:

A system with a stable flow of production may be more valuable than a fast one.

The improvement of the case packer’s productivity in terms of can packaging is more complicated than simply changing the speed of the robot’s work. There are many different factors that affect the real effectiveness of the system.

It is important for those manufacturing companies that plan to automate the process of can packing to consider the case packer’s efficiency within the entire production line. A properly set up robotic case packer can improve the workflow from product infeed to case packing.