Compact Case Packing and Palletising Automation for GMP Pharmaceuticals
Updated: Sep 29
Case Packing and Palletising Designed to Work as One Line
As demand grew across GMP Pharmaceuticals’ dairy and nutritional product lines, the company needed to increase end-of-line capacity within its existing Girraween facility. Fibre King delivered an integrated solution built around two essential stages: a fully automatic Top Loading RSC Case Packer to erect, load and seal cases, followed by a Compact Modular Palletiser (CMP) to form finished pallets. Automated pallet conveying connects the system to the next stage of handling.
The site’s limited floor space shaped both the line layout and the development of Fibre King’s first CMP. Together, the case packer and palletiser gave GMP Pharmaceuticals a practical way to automate repetitive packing and palletising tasks without a major change to its facility layout.
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.
The Case Packer: Consistent Cases for an Automated Line
At the front of the system, Fibre King’s fully automatic Top Loading RSC Case Packer turns incoming products into sealed cases ready for palletising. It erects Regular Slotted Containers (RSCs), loads the products from above and seals each case before transfer downstream. The case packer was configured to handle multiple product formats, with servo-controlled handling supporting consistent packing and case presentation.
Automating these steps reduces the need for manual case packing while giving the CMP a reliable flow of finished cases. Its role is central to the result: the palletiser can only keep the line moving when cases arrive consistently and are ready to handle. By designing and integrating both machines, Fibre King connected case packing and palletising into one coordinated end-of-line process.
Key Features
Fully automatic operation
Top loading configuration
Servo-controlled product handling
Multi-format capability
Compact footprint design
Integrated safety guarding and controls
Reliable operation in a pharmaceutical and nutritional product packaging environment
“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
End-of-Line Performance and Return on Investment
The value of this installation comes from automating the connected tasks at the end of production. The case packer erects, loads and seals cases; the CMP places those cases onto pallets; and the dual-level pallet conveying system supports automatic pallet changeover.
For GMP Pharmaceuticals, that meant less manual handling across the end-of-line process, more consistent case packing and pallet formation, and a system designed to keep production moving within a restricted footprint.
Key operational benefits included:
Automated case erecting, loading and sealing
Consistent cases presented to the palletiser
Reduced manual packing and palletising tasks
Automated pallet changeover with less operator intervention
Better use of the available production space
A connected system that supports continued production growth
"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: A Complete Line Within a Compact Footprint
Fibre King’s solution addressed the full end-of-line requirement at GMP Pharmaceuticals. The Top Loading RSC Case Packer automated the formation and packing of finished cases, while the CMP automated pallet formation in space that could not accommodate a conventional palletising layout. Dual-level pallet conveying completed the flow by moving empty and finished pallets through the system.
Developed for the space constraints of this project, the CMP went on to become a broader Fibre King palletising platform. At GMP Pharmaceuticals, its success depended on the complete line: consistent case packing upstream, compact palletising and automated pallet handling working together.
Planning a Case Packing or Palletising Project?
More formats? Higher throughput? Less manual handling? Tell us what you need to pack, how fast the line needs to run and what space is available. Fibre King can help you assess the right case packing, palletising and pallet handling configuration for your operation.
Explore the full case packer range here: 🔗 https://www.fibreking.com/case-packers
Explore the full palletiser range here: 🔗 https://www.fibreking.com/palletisers
