Case Study: Automated Robotic Crate Palletising, Conveying & Stretch Wrapping System

The Challenge

With nearly two decades of experience automating crate handling systems, Fibre King was selected by a global seafood leader to deliver a state-of-the-art palletising and stretch wrapping solution for their Thai processing facility.

Manual palletising and stretch wrapping had been creating bottlenecks, inconsistent pallet builds, and higher labour costs. The goal was to implement a high-throughput, reliable, and hygienic system that could:

• Automatically collate and palletise crates into stable, repeatable patterns

• Apply crate lids with precision

• Integrate with an automated stretch wrapping process

• Reduce manual handling while meeting strict hygiene and safety standards

The Solution

Fibre King designed and delivered a turnkey robotic palletising and stretch wrapping system, centred around ABB robotic technology and supported by our in-house designed advanced gripper systems and fully integrated conveying solutions.

Proven Expertise in Crate Handling

Since 2006, Fibre King (through its Oryx Automation brand) has led the way in delivering reusable plastic crate and bin handling automation for producers, crate poolers, and FMCG industries. With nearly two decades of specialised experience, Fibre King has developed reliable, scalable systems trusted by global brands to manage crates of all shapes and sizes efficiently.

This long-standing expertise ensured the solution could reliably manage heavy-duty crates with lids, even with the added complexity of precise pallet configurations and secure stacking.

Key Components

• ABB IRB 660 Palletising Robot: Handles high-speed, high-accuracy palletising of crates using a mechanical gripper.

• ABB IRB 460 Robot (Lid Application): Applies crate lids using a vacuum gripper to stabilise loads before wrapping. Lid application is a particularly complex step, requiring accuracy, coordination, and reliability — and was executed seamlessly by the integrated robotic system.

• Fromm FA6 Stretch Wrapper: Automatically stretch-wraps completed pallets for stability during transport.

• Pallet Conveying System: Powered roller and chain conveyors with shuttle conveyors for flexible pallet transfer.

• Collation & Infeed: Crates arrive single file, aligned pneumatically, and indexed for robotic pick-up. Each crate measured 597 × 375 × 192 mm, weighed up to 25 kg, and was designed for stackable palletising in food and beverage FMCG environments. Crates were collated into 35-crate pallets (7 layers of 5 crates) on 1200 × 1000 mm pallets using a 5B2 interlocked pattern.

• Controls & Integration: PLC-controlled with full interlocking, HMI operator interface, and remote access capability for monitoring and troubleshooting.

  
  

Safety & Standards

• ISO9001 compliant, designed to AS4024 Australian safety standards.

• Guarding, interlocks, and positive-locking systems for operator safety.

• Food-grade lubricants and hygienic finishes where required.

The Implementation Process

• Design & Engineering: Full mechanical and electrical design reviewed with client via 3D modelling.

• Manufacturing & Assembly: Built and tested at Fibre King’s facility.

• Factory Acceptance Testing (FAT): Joint testing with client prior to shipment.

• Installation & Commissioning: On-site by Fibre King engineers.

• Site Acceptance Testing (SAT): Final validation at the customer’s facility before handover.

The Outcome

• Throughput: Up to 17 pallets per hour at 10 crates per minute.

• Consistency: Precise robotic handling ensures repeatable, stable pallet builds.

• Efficiency: Significant reduction in manual labour and operational downtime.

• Safety: Automated system reduces operator exposure to repetitive strain and manual handling risks.

• Complexity Achieved: The challenging lid application process — often a pain point in automated systems — was executed with exceptional accuracy and reliability.

• Scalability: System integrates with upstream and downstream processes for future expansion.

Delivered to a global seafood leader in Thailand, this project demonstrates how Fibre King combines innovative robotics, robust engineering, and decades of automation expertise to solve complex end-of-line challenges. With experience handling crates of all shapes and sizes since 2006, Fibre King was able to deliver a solution that not only automated palletising and wrapping but also mastered the intricate task of lid application.

Backed by nearly a century of engineering excellence and over 75 years at the forefront of FMCG automation, Fibre King has a proven history of pioneering world-class packaging solutions. From Australia’s first packaging machinery in 1950 to today’s fully integrated robotic systems, Fibre King continues to deliver future-ready automation that is safer, more reliable, and built to last — trusted by FMCG leaders worldwide.