file into both robotic cells, ready for
automated case loading.
“Brillopak’s robot is impressive to watch.
It never misses a beat and is capable
of orientating packs quicker than any
person is able to do,” comments Andy
This level of presentation precision
was one of the key drivers behind
automating the case loading operation
at Rushden. Previously, potato packs
were loaded manually into crates. It
was labour intensive, incurred packing
bottlenecks and resulted in messy tray
presentation.
STAFF SATISFACTION
Having worked on both the manual
packing and now automated lines,
machine operative Dave reflects on the
differences the robot cells have made to
workers and waste.
Noting that the UniPaker cell is much
more product and user friendly, Dave
comments: “By removing 90% of the
physical labour from the packing
production area, health & safety
and people’s approach to teamwork
has improved. It’s a much calmer
environment and so much better for
staff welfare. It’s almost hypnotic to
watch when the robots are running.”
Additionally, with the introduction of
the robotic lines and glove end effector,
Dave reports less product rework as a
result of split bags.
A simple, intuitive HMI means that it’s easy for operatives to select the correct programme and
case loading patterns for product changeovers
David adds: “Suctioning polybags of
heavier potatoes with varied shapes is
equally challenging. Because it’s not a
smooth surface, bags frequently sag and
drop onto the packing conveyor, causing
the packing line to stop. These frequent
line stops have a significant impact on
line efficiency and ultimately bottom line
profit.”
Rather than using stainless steel,
which would add to the weight being
repeatedly lifted, Brillopak designed
the end-effector using soft food-grade
material.
DELTA DEXTERITY
For this Morrisons potato packing line,
Brillopak installed two specialist four-
arm Spider (Delta) robots within each
robotic cell. Each robot has a payload
of 5kg, including a head with rotation
functionality. In most fresh produce
applications a three-arm robot will offer
sufficient payload highlights David.
With a reach of 1130mm - 30% more
than similar sized robots - the UniPaker
system delivers dexterity in a compact
footprint. Rumble conveyors settle
the packs and deliver them in single
Describing the robot lines as easy to
operate, Dave says the system set up
and HMI is intuitive to use, particularly
for product changeovers. Having been
involved in writing guidelines for team
members to reference he affirms: “It’s
so straightforward to use that I’m never
worried about pressing the wrong
button and breaking the system!”
Forming part of a site-wide investment
in front and back end manufacturing
improvements, the Rushden site
has seen improvements in Overall
Equipment Effectiveness (OEE). Andy
attributes these improvements to
the increased packing speed, better
presentation, less front to back end
bottlenecks and fewer staff frustrations.
www.brillopak.co.uk
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