Australia’s Smallest Palletiser Incorporated into End-of-Line Automation for Nutritional Powder Manufacturer: GMP Pharmaceuticals

The Project That Led to the Development of Fibre King’s Compact Modular Palletiser (CMP)

Fibre King’s Compact Modular Palletiser provides a flexible, affordable and compact palletising solution that is proving popular within Australian facilities.

As production demand increased across GMP Pharmaceuticals’ dairy and nutritional product lines, the company required a smarter, fully automated end-of-line packaging solution capable of improving throughput without expanding its production footprint.

Working closely with GMP Pharmaceuticals at their Girraween, NSW facility, Fibre King delivered an integrated end-of-line automation system combining advanced case packing and palletising technology within an exceptionally compact layout.

Importantly, this project became the catalyst for the development of Fibre King’s Compact Modular Palletiser (CMP) platform.

During consultation phase, it became clear that conventional palletising systems would not meet the space constraints or operational requirements of the facility. GMP Pharmaceuticals required a fully automated palletising solution capable of maintaining production throughput within an exceptionally limited footprint — without compromising reliability, operator safety or future scalability.

In response, Fibre King engineered an entirely new compact palletising platform specifically for this application.

The result was the first Compact Modular Palletiser (CMP), developed and deployed as part of the GMP Pharmaceuticals installation and marking the Australian debut of the system in 2017.

The Challenge: Increase Output Within a Restricted Footprint

GMP Pharmaceuticals specialises in the manufacture and packaging of healthcare, natural health and dairy products. As production volumes increased, the business required an automated end-of-line solution capable of supporting continued operational growth while reducing manual handling and improving production efficiency.

Space limitations within the facility presented a significant challenge.

Traditional palletising systems and conveyor layouts were not suitable for the available production area, requiring a highly compact automation solution capable of integrating seamlessly into the existing production environment.

The Solution: Integrated Case Packing and Compact Palletising

Fibre King designed and delivered a complete automated end-of-line system incorporating:

• Fibre King Top Loading RSC Case Packer

• Fibre King Compact Modular Palletiser (CMP)

• Automated dual-level pallet conveying system

• Integrated line controls and product handling

The solution automated the complete end-of-line process — from carton loading through to finished pallet handling — creating a streamlined and highly efficient packaging operation.

Fibre King Top Loading RSC Case Packer

At the front end of the solution, Fibre King supplied a fully automatic Top Loading RSC Case Packer engineered specifically for pharmaceutical and dairy product handling applications.

The system automatically erects, loads and seals Regular Slotted Containers (RSCs) with precise product handling and consistent pack quality.

Designed for reliability and flexibility, the case packer accommodates multiple product formats while maintaining gentle product handling and efficient line speeds.

Key Features

• Fully automatic operation

• Top loading configuration

• Servo-controlled product handling

• Multi-format capability

• Compact footprint design

• Integrated safety guarding and controls

• Pharmaceutical-grade operational reliability

The case packer was fully integrated with the downstream palletising system to create a seamless automated packaging line.

“The complete Fibre King system has exceeded our expectations in both performance and reliability. The compact design allowed us to automate our end-of-line operations without requiring significant changes to our existing facility layout.”— GMP Pharmaceuticals

Development of the Compact Modular Palletiser (CMP)

The GMP Pharmaceuticals project directly led to the development of Fibre King’s Compact Modular Palletiser platform. Designed specifically to solve the site’s space constraints, the CMP was engineered as a compact, modular palletising solution capable of delivering high-performance automation within a minimal footprint.

Designed for low- to mid-speed applications, the CMP features a pick-and-place vacuum gripper mounted to a cantilevered gantry-style mechanical structure. Combined with advanced multi-axis servo control, the system provides accurate and flexible palletising across a wide range of pack formats while maintaining an extremely compact footprint.

The vacuum gripper head incorporates a fourth rotational axis, allowing complete freedom of movement and flexible pallet pattern configuration.

What began as a custom-engineered solution for GMP Pharmaceuticals ultimately evolved into a broader Fibre King palletising platform now used in applications where manufacturers require high-performance automation within limited floor space.

Compact Design Without Compromising Performance

Because floor space was heavily constrained, the system could not rely on long accumulation conveyors or manual pallet exchange procedures.

“As space was constrained, the facility could not enjoy the luxury of accumulating cases on a long conveying system. This required the pallet changeover to be swift, so as not to stop the upstream equipment.”— James Windsor, Fibre King

To maintain continuous line operation, Fibre King integrated a dual-level pallet infeed and outfeed conveyor system that automated pallet exchange operations.

This configuration allows operators to load empty pallets onto a low-level conveyor while completed pallets are automatically discharged via the elevated outfeed system.

“With a dual-level pallet conveying system in place, the line can run continuously without being reliant on an operator being on permanent stand-by.”— James Windsor, Fibre King

Compact Modular Palletiser (CMP) Specifications

Key Features

• Fully automatic operation

• Compact 2m x 3m footprint

• Up to 15 cases per minute

• Pick-and-place vacuum gripper system

• Gantry-style mechanical structure

• Multi-axis servo control

• Flexible pallet configuration capability

• Low noise operation (<80dB)

• PLC controlled with full interlocking and automatic sequencing

• Left or right-hand product handling configurations

• Future-ready modular layout for relocation or expansion

Product Handling Capability

The CMP is designed to handle:

• Cases / Cartons

• Shrink-wrapped packs

• Drums

• Crates

Optional Features

• Multiple pallet size capability

• Stretch wrapping integration

• Over-under pallet conveyor for automatic pallet changeover

• Empty pallet dispenser

• End or side loading functionality

Performance & Return on Investment

The fully automated Fibre King system delivered immediate operational improvements for GMP Pharmaceuticals by reducing manual handling requirements, improving production efficiency and supporting continuous line operation.

Key operational benefits included:

• Increased end-of-line throughput

• Reduced labour dependency

• Improved production reliability

• Continuous automated pallet handling

• Reduced operator intervention during pallet changeover

• Improved factory space utilisation

• Scalable automation platform for future growth

The compact integrated design also enabled GMP Pharmaceuticals to achieve automation outcomes that would not have been possible using conventional palletising systems within the same production footprint.

"To match the palletising performance of the CMP, manufacturers typically require two to three operators plus a forklift driver per shift. With a CMP installed, no full-time palletising operator is required, allowing labour to be redeployed to higher-value tasks. When integrated with automated pallet handling and stretch wrapping, forklift intervention can also be eliminated. Conservatively, labour savings of approximately $250,000 per year across two shifts can deliver payback on a CMP system with basic pallet handling in as little as eight months." - James Windsor, CEO Fibre King

Key Operational & Technical Benefits

High Throughput Performance

The CMP is capable of operating at up to 15 pick-and-place cycles per minute.  Combined with precision multi-axis servo control and short travel distances, the system delivers highly efficient palletising performance within a compact footprint.

Reduced Labour Requirements

A major operational benefit was the reduction in manual labour requirements for up to three full time operators, further labour savings are possible when combined with automated pallet handling.

Compact Footprint & Space Efficiency

The system delivered significant space-saving advantages. The CMP requires approximately 50% less floor space than a comparable high-level mechanical palletiser and approximately 60% less space than a comparable robotic palletiser, making it particularly suitable for facilities with restricted layouts.

Flexible Operator-Controlled Pallet Patterns

Additional operational efficiencies were achieved through Fibre King’s pallet pattern generation software, which allows operators to create and modify pallet patterns directly through the HMI without requiring specialist programmers or external support visits. This provides greater flexibility for packaging updates, promotional configurations and new product introductions while reducing ongoing support costs.

Predictive Maintenance & Reduced Downtime

The CMP incorporates predictive maintenance software as standard, providing operators with early warning notifications as components approach the end of their service life. This enables planned maintenance scheduling and helps minimise costly unplanned downtime, particularly important given the palletiser’s position at the end of the production line.

Remote Monitoring & Technical Support

Remote monitoring capability further supports operational reliability, allowing Fibre King engineers to monitor system performance and assist with troubleshooting remotely when network access is available. This feature is particularly valuable for regional and remote manufacturing facilities by reducing service response times and minimising the need for site visits.

Energy Efficient Operation

Energy efficiency was also a key consideration in the system design. The CMP utilises energy-efficient components and compressed air monitoring technology to detect leaks and reduce unnecessary energy consumption. With an average connected load of approximately 3kWh, the CMP consumes around one fifth of the power used by the average family home.

Results

By partnering closely with GMP Pharmaceuticals, Fibre King delivered a fully integrated automation solution that improved production efficiency, reduced manual handling requirements, and supported long-term operational growth — all within a highly constrained production environment.

The project not only solved an immediate operational challenge but also led to the development of Fibre King’s Compact Modular Palletiser platform, which continues to support manufacturers requiring high-performance palletising automation within limited floor space.

Today, compact and scalable automation solutions like the CMP remain an important part of modern manufacturing environments where operational efficiency, flexibility and footprint optimisation are critical.

Looking for a Smarter Palletising Solution?

The Fibre King CMP delivers high-performance automated palletising in a compact footprint — helping manufacturers improve throughput, reduce labour dependency and maximise factory space.

Fibre King also designs and manufactures high-level mechanical palletisers, robotic palletising systems and complete end-of-line automation solutions tailored to your production requirements.

Contact Fibre King to discuss the right palletising solution for your operation.

Explore the full palletiser range here:  🔗 https://www.fibreking.com/palletisers

View more information on the CMP here: 🔗 https://www.fibreking.com/cmp-compact-modular-palletiser

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