Increasing Production Capacity with Robotic Layer Palletising for Shelf-Ready Packaging

14 hours ago

5 min read

Fibre King robotic layer palletising system for shelf-ready packaging during factory run-up — Layout of two layer-forming lines feeding one robotic palletiser with automated pallet handling and stretch wrapping

New packaging formats shouldn’t hold back production. Neither should the palletising system handling them.

For one food manufacturer, introducing new shelf-ready packaging meant addressing two challenges at once: increased production rates and case formats that required greater handling control. The existing palletising capability could not accommodate the new requirements. Some cases were tall relative to their footprint, creating potential instability during conveying, turning and pallet layer formation. The manufacturer selected Fibre King’s integrated robotic palletising solution to address these requirements.

The project is now underway, connecting two flexible layer-forming lines, a shared ABB robot, automatic pallet handling and stretch wrapping. Its non-vacuum layer gripper also gives the manufacturer greater freedom to increase recycled cardboard content, while accommodating packaging formats that are traditionally difficult to handle.

The Challenge: Increase Output While Controlling Shelf-Ready Cases

For site and production managers, a packaging change affects far more than the pack itself. Different dimensions, proportions and pallet patterns can change how reliably products move through the end of the line. The manufacturer needed to handle new tray products at higher production rates, with flexibility to accommodate future contract manufacturing requirements and different packaging formats. The site also needed an efficient way to supply empty pallets, remove completed loads and prepare them for collection. Increasing robot capacity alone would not address delays elsewhere in that process.

The key requirements were to:

Support increased production rates.
Handle multiple case sizes and pallet patterns.
Control potentially unstable shelf-ready cases.
Automate empty-pallet supply and completed-pallet removal.
Integrate stretch wrapping into the production flow.
Position pallet input and collection points near existing operations to streamline forklift movements.
Maintain practical access for operators and maintenance.

Fibre King’s turnkey solution addresses the complete flow from incoming cases to wrapped-pallet collection.

The Fibre King Solution

The system combines two dedicated layer-forming lines with one ABB IRB 760 palletising robot. Cases arrive from high-level conveying and are conveyed via a spiral lowerator into the palletising area before being distributed between the two lines. Each line orients and arranges cases into the selected pallet pattern, then presents a complete layer for the robot to transfer. Automatic pallet dispensing, shuttle handling and in-line stretch wrapping coordinate the movement of pallets through the system.

The integrated solution includes:

Spiral lowering and case distribution.
Accumulation and metering conveyors.
Automatic case orientation and row formation.
Layer building and squaring.
Full-layer robotic palletising.
Empty-pallet dispensing and orientation.
Dual-level pallet shuttle handling.
Automatic stretch wrapping and outfeed conveying.
Integrated controls, diagnostics and safety guarding.

Controlled Infeed to Support Production Flow

Higher throughput requires consistent product delivery into the palletising system.

An AmbaFlex spiral lowerator transfers cases from the high-level infeed to the palletising area. A metering conveyor controls their arrival at an Intralox switching system, which directs cases to either of the layer-forming lines or a reject conveyor when required.

Accumulation conveyors provide a buffer ahead of each line, while metering regulates the delivery of cases into row formation. This arrangement helps manage variations in product arrival and provides controlled feeding into the layer-building process.

Layer Formation Built Around Shelf-Ready Packaging

Shelf-ready packaging needs to move reliably through the factory as well as present effectively on the retail shelf.

For this project, case proportions and stability are central to the handling design. Selective diversion and turning position cases according to the chosen pallet pattern. An overhead pusher transfers completed rows into the layer-building area, where the full layer is squared before moving to the robot pick position. eparate layer-building and pick positions allow the next layer to be prepared while the robot handles a completed layer. This separates product collation from robotic transfer to support the required production flow. The design also addresses pallet patterns requiring adjustment to avoid case overhang.

Handle Challenging Packaging While Supporting Sustainability Goals

Shelf-ready cases, open-top trays and tray-and-shrink packs can be difficult to palletise with vacuum gripping. Variations in cardboard porosity and recycled content can affect the seal needed for reliable vacuum pickup. Fibre King’s full-layer gripper supports the product from beneath, without relying on vacuum suction or an airtight cardboard surface. During pickup, a supporting deck closes beneath the layer as it enters the gripper. The gripper squares the layer during transfer, then retracts the deck to place it onto the pallet. This approach provides greater flexibility to handle traditionally challenging packaging formats, including:

Shelf-ready cases.
Open-top trays.
Tray-and-shrink packs.
Cardboard packaging with higher recycled content.

For the manufacturer, this creates an opportunity to increase recycled cardboard content without relying on the board’s ability to maintain a vacuum seal. Packaging must still provide sufficient structural strength for conveying and stacking. The result is a handling solution that supports production requirements and packaging sustainability goals together.

Automatic Pallet Handling to Minimise Exchange Delays

A palletising system needs the next empty pallet ready when the current load is complete. The solution includes a magazine holding up to 15 empty pallets, with automatic dispensing of Australian standard CHEP or Loscam pool pallets. A lift-up rotator provides the correct orientation before the pallet enters the system.

Dual-level shuttle handling supplies empty pallets on the lower level and removes completed loads on the upper level. Staging empty pallets ahead of the next loading cycle is designed to minimise interruptions during pallet exchange. Pallet conveying enters and exits from the same side, supporting ground-level access to the cell.

For the production team, pallet supply and removal become coordinated parts of the automated process.

Integrated Stretch Wrapping and Collection

Completed pallets transfer directly to an in-line rotating-arm stretch wrapper before moving onto the outfeed conveyors for collection. Powered film pre-stretch and automatic film cut-and-wipe functions form part of the wrapping process. Connecting palletising and wrapping reduces the need for separate handling between these stages. Positioning pallet input and output locations close to the existing system also supports efficient operator and forklift movements. The result is a layout designed around how products and pallets need to move through the site.

Controls and Support for Daily Operation

An Allen-Bradley PLC coordinates operating sequences and interlocks across the palletising system. The HMI provides recipe selection, operating status and fault diagnostics, supported by a recorded status log and password-protected maintenance access. Guarding and trapped-key isolation are incorporated into the robot loading area. Remote-access capability allows technical diagnostics and support when connected to the site network. hese features support operators and maintenance teams in managing production, identifying faults and accessing the equipment.

Project Underway: Supporting the Next Stage of Production

Fibre King’s solution has been selected, and the project is underway to deliver the manufacturer’s upgraded palletising capability.

The system brings case handling, layer formation, pallet movement and wrapping into one coordinated solution, with the following operational benefits targeted after commissioning:

Increased production capacity: Palletising capability designed around the new product and throughput requirements.
Controlled shelf-ready case handling: Case orientation, layer squaring and supported transfer suited to the packaging mix.
Reduced manual handling: Automated palletising, empty-pallet supply and completed-load movement.
Fewer pallet exchange delays: Coordinated delivery of empty pallets and removal of completed loads.
Connected downstream operations: Direct transfer from palletising through wrapping to collection.
Efficient site movements: Pallet input, output and equipment access aligned with existing operations.
Support packaging sustainability goals: Enable greater use of recycled cardboard without relying on its suitability for vacuum gripping.
Handle challenging packaging formats: Support shelf-ready cases, open-top trays and tray-and-shrink packs from beneath.

For food manufacturers facing similar changes, this project highlights the importance of planning packaging formats, palletising capacity and pallet logistics together.

Integrated Palletising and Local Lifecycle Support

Fibre King designs and integrates robotic palletising systems around the products being handled, the required throughput and the available factory space. As an Australian-owned business, Fibre King provides in-house design, engineering and integration, backed by local engineering and service support across Australia and New Zealand.