Multi-Line Food Packaging Automation & Centralised Palletising System
Updated: Sep 21
A major Australian food manufacturer needed to automate palletising across four production lines operating in separate areas of its Victorian facility. Manual pallet movement, regular forklift interaction and disconnected end-of-line processes were restricting efficiency and creating barriers to future production growth.
Fibre King designed and delivered a fully integrated centralised palletising system incorporating four Compact Modular Palletisers, intelligent case conveying, barcode-controlled product routing, automated pallet handling and stretch wrapping.
The coordinated system now moves products from multiple production areas into one central palletising hub—reducing manual handling, separating forklift traffic from operational staff and giving each production line dedicated palletising capability.
Engineering a smarter end-of-line solution
Following detailed consultation with stakeholders and a comprehensive review of the available floor space, Fibre King developed a centralised modular palletising hub built around four Fibre King Compact Modular Palletisers (CMPs).
Designed and manufactured by Fibre King as part of the company’s palletising systems offering, the CMPs were selected for their compact footprint, operational flexibility, independent line function (compared to a central robotic solution) and reliable performance across multiple production lines. Manufacturing the palletisers in-house also enabled Fibre King to tailor the solution specifically to the operational requirements of the facility while ensuring seamless integration across the broader automation system.
The project was designed to streamline product flow, automate pallet handling and reduce forklift traffic throughout the operational area while creating a scalable platform for future production growth.
“Projects like this are about much more than palletising,” said Fibre King.“It’s about understanding touchpoints in the current process and engineering an automation solution that improves the overall operation.”
Site feedback throughout the project also reinforced the value of working with an Australian automation partner. Having direct access to local engineering expertise, responsive support and a team that understood the operational requirements of Australian food manufacturing environments was seen as a significant advantage throughout the delivery process.
“We often hear from customers that they’ve experienced challenges working with offshore suppliers where support and responsiveness can become difficult,” Fibre King said.“Being Australian designed and engineered means we can work closely with customers throughout the entire project lifecycle and provide ongoing support long after commissioning.”
The final solution integrated automated conveying, intelligent product sorting, Fibre King palletising technology, pallet handling and stretch wrapping into one coordinated end-of-line system.
Project scope
The centralised palletising solution included:
Four Fibre King Compact Modular Palletisers (CMPs)
Automated pallet dispensing, handling and transfer system
Spiral Lowerator Conveyors
Intelligent case conveying and sorting
Automated pallet shuttle system
Barcode identification and product routing
Integrated stretch wrapping system
Centralised controls and safety systems
Installation, commissioning and operator training
Four Dedicated Palletisers Provide Built-In Redundancy
During the design phase, Fibre King also evaluated alternative palletising approaches, including a single robotic palletising system servicing multiple production lines.
While robotic palletising was considered, the final solution was intentionally designed around four dedicated Fibre King CMP palletisers — one assigned to each production line.
This approach provided an important layer of operational redundancy across the facility. By decentralising palletising operations, the manufacturer could continue running unaffected production lines even if maintenance or downtime occurred on another line.
“In high-volume food manufacturing environments, operational uptime is critical,” Fibre King said.“Designing the system with dedicated palletising capability per line gave the customer greater flexibility and significantly reduced the risk of a single point of failure impacting the broader operation.”
The approach also provided improved line independence, simplified product flow management and greater flexibility for future production scheduling and expansion.
Intelligent Case Conveying and Barcode-Controlled Routing
To support efficient product flow from multiple production areas, Fibre King engineered an integrated conveying and sorting network designed to feed products into the central palletising system.
Products from the sauce and pasta operations were conveyed through automated spiral lowerators before entering the palletising area, while separate conveying infrastructure managed product flow from the remaining production lines.
Automated sorting technology and barcode identification systems enabled products to be directed to the appropriate palletising lanes, helping streamline end-of-line handling across the facility.
The modular design also provides flexibility for future throughput increases and system expansion as operational requirements evolve.
Compact Palletising for Multiple Products and Carton Formats
At the centre of the installation were four Fibre King Compact Modular Palletisers.
Designed for applications requiring flexibility, reliability and compact footprint efficiency, the CMP systems automatically pick and place cartons onto pallets using Fibre King’s gantry-style vacuum picking technology.
The palletisers were configured to accommodate multiple carton sizes and pallet patterns while allowing rapid product changeovers between production runs.
“Manufacturers are increasingly dealing with greater product variation and changing production demands,” Fibre King explained.“The ability to adapt quickly while maintaining reliable throughput was a key focus of this project.”
The system also incorporated automated pallet exchange functionality, allowing completed pallets to transfer directly into the pallet handling network while new pallets were introduced without interrupting production flow.
Automated Pallet Handling Reduces Forklift Traffic
A major objective of the project was reducing forklift interaction within operational areas.
To achieve this, Fibre King delivered a fully integrated pallet transport and handling system incorporating automated pallet dispensing, powered pallet conveyors, dual-level shuttle transfer technology and pallet accumulation leading into stretch wrapping and dispatch.
Completed pallets were automatically transferred into a rotating arm stretch wrapping system, helping improve load consistency and operational efficiency across the facility.
The result was a cleaner, safer and more streamlined end-of-line operation with improved product flow throughout the production environment, and segregated forklift movements from operational staff.
The Results: A Safer, More Scalable End-of-Line Operation
The completed system consolidated palletising and pallet handling from four production lines into one coordinated automation platform.
Dedicated palletisers allow each line to operate independently, reducing the risk of a single equipment issue affecting the wider production operation. Automated conveying, pallet transfer and stretch wrapping also reduce manual handling and separate forklift movements from operational staff.
Key operational outcomes included:
Automated palletising across four production lines
Reduced and segregated forklift traffic
Less manual carton and pallet handling
Independent palletising capability for each line
Improved end-of-line product flow
Automated pallet dispensing, transfer and stretch wrapping
Flexibility to accommodate multiple carton formats and pallet patterns
A modular platform capable of supporting future production growth
Planning a Multi-Line Palletising Project?
Multiple lines, different products and too much manual handling at the end of production?
Tell us what each line produces, the required throughput, carton formats, pallet patterns and site constraints. Fibre King will develop a practical palletising concept with an indicative budget and delivery timeframe.
1300 831 330, +61 73293 8800
