Multi-Line Full-Layer Robotic Palletising for Food Manufacturing

An integrated solution connecting three production lines to one automated palletising, wrapping and labelling system

As part of an upgrade to its end-of-line operations, a major Australian food manufacturer in New South Wales selected Fibre King to design and deliver a centralised automated palletising system tailored to its existing facility.  The project will bring together the output of three production lines, replacing separate product flows with one coordinated palletising process.

Working within the constraints of the existing factory layout, Fibre King developed a centralised full-layer robotic solution designed to manage multiple carton formats and the differing requirements of each line. The complete system will automate carton conveying, layer formation, palletising, pallet handling, stretch wrapping and labelling, creating a streamlined process from packed carton through to finished pallet.

The system is currently being installed, with commissioning and production ramp-up to follow.

The Customer’s Challenge

The manufacturer needed to automate palletising across three production lines to reduce manual handling, improve end-of-line efficiency and support future production requirements—without the cost and disruption of major changes to the existing factory layout. Two lines discharged cartons onto existing high-level conveyors, while a third connected to a new case packer in another production area. The challenge was to bring all three carton flows into a shared palletising zone while maintaining controlled product presentation, sufficient accumulation and reliable throughput across the operation.

The system also needed to:

• Handle six carton configurations and multiple pallet patterns

• Process line speeds of up to approximately 41 cases per minute

• Form consistent layers containing either 25 or 50 cartons

• Automatically supply and exchange pallets

• Apply plastic pallet boards when required

• Consolidate stretch wrapping and pallet labelling

• Maintain suitable access for operators, maintenance and forklift collection

• Integrate the complete process through one control system

The challenge extended beyond robotic palletising. Fibre King needed to engineer the movement of cartons and pallets through the entire end-of-line process.

The Fibre King Solution

Fibre King designed a centralised system built around three dedicated full-layer forming stations and one ABB IRB 660 palletising robot.

Each production line feeds its own layer former, allowing cartons to be independently arranged into the required pallet pattern. When a full layer is ready, the robot moves to the relevant station, picks the complete layer using a vacuum assembly and places it onto the waiting pallet.

The integrated system includes:

• Low- and high-level carton conveying

• Spiral elevating and lowering conveyors

• Low-back-pressure accumulation

• Three full-layer forming stations

• ABB robotic palletising

• Automatic empty-pallet dispensing

• Plastic pallet-board application

• Automated pallet alignment and exchange

• Full-pallet conveying

• Automatic stretch wrapping

• Automatic pallet labelling

• Finished-pallet accumulation

• Centralised controls, guarding and remote-access capability

Fibre King is responsible for integrating each element into one coordinated system, from the production-line outfeeds through to wrapped and labelled pallet collection.

Conveying Around Existing Equipment

Each production line required a different conveying route into the central palletising area. Cartons from the first two lines transfer from existing high-level conveyors onto new decline conveyors. These deliver the cartons directly to their respective layer-forming stations.

Cartons from the third line exit a new case packer at low level before entering a spiral elevator. They are raised to approximately 3,600 mm and conveyed above existing machinery using transport and low-back-pressure accumulation conveyors. A second spiral then lowers the cartons into the palletising area.

Using the available overhead space allowed the new system to connect the production areas without significantly disrupting the equipment below. A horizontal conveyor section also provides a manual palletising pick-off point if the downstream system is unavailable.

Full-Layer Robotic Palletising

The three layer-forming stations arrange cartons into programmed patterns containing either 25 or 50 cartons, depending on the selected product.

Once a layer is complete, the station requests the robot on a first-ready basis. The ABB IRB 660 travels to the pick position, engages the vacuum assembly and transfers the complete layer to the corresponding pallet. Each finished pallet contains six layers.

This approach allows one robot to efficiently service all three lines while maintaining independent layer formation for each product stream. Accumulation upstream of the layer formers helps manage variations in carton arrival and maintain controlled product flow.

Recipes managed through the HMI determine the carton pattern and whether a plastic pallet board is required for the selected product.

Automatic Pallet Handling

A forklift loads a stack of up to 15 empty pallets onto an infeed conveyor outside the guarded area. Once the first stack enters the pallet dispenser, another can be loaded, providing capacity for up to 30 empty pallets.

The dispenser separates the bottom pallet and transfers it to an aligning station. When required by the product recipe, a plastic pallet board is automatically placed onto the pallet before it enters the robotic loading position.

A dual-level shuttle manages the exchange of empty and completed pallets. When palletising is complete, the full pallet exits the loading position and is replaced by the next empty pallet. The shuttle then transfers the completed load to the shared wrapping line.

Automating this process reduces manual pallet handling and minimises delays between completed loads.

Integrated Wrapping and Labelling

Completed pallets from all three lines are consolidated through one downstream process.

Before wrapping, each pallet is scanned so the manufacturer’s system can generate the appropriate label data. The pallet is then automatically stretch wrapped, labelled and conveyed to a collection point ready for forklift removal.

This removes the need for separate wrapping and labelling equipment at each production line and provides a consistent final handling process.

Controls, Safety and Support

The complete system is controlled by an Allen-Bradley PLC, with automatic sequencing and interlocking between the conveyors, layer formers, robot, pallet-handling equipment, wrapper and labeller.

The HMI provides product recipe selection, operating status, fault identification and password-protected maintenance access. Potential stop conditions, including a low supply of empty pallets, are detected and communicated to operators before production is interrupted.

Remote-access capability will allow Fibre King engineers to assist with diagnostics and technical support when the system is connected to the customer’s network.

Safety guarding, electrically interlocked access doors and monitored safety functions are incorporated throughout the palletising and pallet-handling areas.

The Outcome

Following installation, commissioning and production ramp-up, the new system is expected to provide:

• Automated palletising across three production lines

• Efficient handling of line speeds up to approximately 41 cases per minute

• Consistent carton layers and finished pallet patterns

• Reduced manual palletising and pallet handling

• Automatic pallet dispensing, alignment and exchange

• Automatic pallet-board application

• Improved use of the available factory space

• Consolidated stretch wrapping and pallet labelling

• Improved visibility of system performance and faults

• One point of responsibility for the complete end-of-line system

By using overhead conveying and a shared robotic palletising platform, Fibre King has developed a solution that works around the manufacturer’s existing equipment while avoiding unnecessary duplication.

The result will be a coordinated end-of-line process designed around the customer’s products, production rates and operating environment.

Integrated Palletising from One OEM

Complex palletising projects depend on more than selecting the right robot. Conveying, accumulation, layer formation, pallet movement, wrapping, labelling, safety and controls must operate as one system.

As an Australian-owned OEM, Fibre King designs and integrates complete end-of-line automation solutions and provides ongoing engineering, service and lifecycle support across Australia and New Zealand.

Let’s Talk About Your Line

Whether you are automating one production line or consolidating several lines into a centralised palletising system, Fibre King can develop a solution around your products, required throughput, pallet formats and factory layout.

Talk to the Fibre King team about your next palletising or end-of-line automation project.

1300 831 330+61 7 3293 8800