Assembly line work 4.0 – thanks to KUKA palletizing robot

A fully automatic palletizing system, in which a KR QUANTEC PA from KUKA stacks the boxes, ensures satisfaction at an Australian company for body care products. The palletizing robot supports employees efficiently and safely in the heavy physical work – and does so at a constant speed and without tiring. The system was installed by KUKA systems partner Scott.

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KUKA palletizing cell stacks boxes fully automatically

Box by box, stack by stack: at an Australian body care products manufacturer, the stacking of production goods is performed by a fully automatic system implemented by KUKA systems partner Scott. The solution: In a double automation cell, a KUKA KR QUANTEC PA now stacks the large boxes one after the other on the assembly line.The customer not only benefits from the high reliability and efficiency, but also increases the safety of the employees by using the robot for stacking.

Fully automatic stacking with palletizing cell

Separated from the factory workers by a safety fence, the palletizer takes one box after the other from the conveyor system and stacks them in a specific pattern on the waiting pallet. Once the pallet is fully stacked, the safeguard at the rear of the palletizing system is raised so that the operator can remove the finished stack. In the meantime, the robot continues stacking in the adjacent second cell. Thanks to the intelligent double cell system, the production line is not interrupted at all, and the implemented safety systems allow the warehouse staff to access the cell when it is not in use.

Reliable partner for robots and palletizing systems

KUKA has been a long-time partner for the robot integrator Scott. One reason for this: the quick global availability of the robots. Scott took delivery of the completed palletizing cell just 14 weeks after the initial contact. “The flexibility of KUKA’s approach and their speed in processing this project was a key factor in choosing KUKA as our robotics partner,” says Simon Parker, Scott Industrial Automation Sales Manager. The machine selected by KUKA allowed Scott to supply the customer a compact palletizing cell with both a simple design and high cost-effectiveness.

KR QUANTEC offers versatility in stacking

The KR QUANTEC PA from KUKA is the optimal solution for the fully automated end-of-line palletizing and stacking application. The customer was looking for a means of fully automating the manual stacking process and reducing labor costs while simultaneously increasing employee safety. “The customer needed a compact robotic palletizing system that could be implemented quickly and with very little effect on the existing production lines. The key was a palletizing cell which would allow the stacked pallets to be removed without stopping production,” states Simon Parker. Scott developed a flexible automation solution that not only stacks different boxes fully automatically, but also allows safe access to the palletizing cell to remove stacked pallets without interrupting the process.

Palletizing system from KUKA as a cost-saving solution

Scott was also able to meet another customer requirement: a modular palletizing system that takes up only a small amount of space in the production hall. Thanks to the compact footprint, streamlined base frame and minimal disruptive contour of the KR QUANTEC PA, the palletizing cell takes up very little space in the production facility – the high work output is nevertheless impressive: The KUKA robot can stack up to 30 different boxes per minute with a maximum stack height of 2.40 meters. 

Full productivity with no breaks

The automated palletizing also ensures that the boxes stacked on top of each other are positioned evenly to avoid products falling off or pallets being loaded lopsided. Furthermore, the palletizing cell operates at a constant speed, without a break or interruption. The customer is highly satisfied with this system offered by Scott and KUKA. The requirements – lower production costs, reliable handling of different stacked boxes and greater safety for employees – were met in full.

Leading the way in robot palletizing flexibility & technology

Palletizing for

No matter what type of product needs palletizing, MCRI has successfully stacked it. And we can help you start stacking.
From a simple, one robot cell to more complex multi- robot palletizing systems, we develop your robotic palletizing system to be the optimal solution for your process. Our easy-to-use robot palletizing systems:

• increase your throughput while reducing operating costs and floor space.
• decrease employee ergonomic & harsh environment injuries.
• increase quality with improved product tracking.
• bring flexibility to your process by adding easy changeover options.
• are low maintenance systems with high reliability & superior up-time.

We Are There with You

Our years of integrating robots has proven the importance of the integrator being there to collaborate and answer questions.

1. We start with robotic 3D simulations for concept verification
2. Continue by providing a constant communication network through your project manager
3. Run Factory Acceptance Testing before shipping
4. Provide on-site training with first run
5. And we leave you with 24/7 support after install

What can you expect from any MCRI palletizing system?

• Systems are built around highly reliable FANUC robots with payload capabilities up to kg (includes EOAT weight).
• A vertically integrated facility to supply peripheral equipment and keep your project on schedule.
• Recipes for storing part data such as product size, packing pattern, place locations and vacuum pattern.
• Product data tracking through barcode readers.
• Easy to navigate Human Machine Interface (HMIs) for recipe adjustments, pattern teaching, and error reporting.
• Robotic vision systems for product inspection, part location, line tracking, and more.
• Custom built slip sheet racks, pallet racks, or automated pallet dispensers.
• Sensors to regulate process: safety sensors, pallet present, product present, stack height, and other needs.
• Custom multifunction end effectors that can handle pallets, bottom sheets, top sheets, trays, and/or top frames with no need for a tool change.
• Finished pallet takeaway with pallet conveyor or SmartCart AGCs.
• Upstream processing to prepare or sort product for palletizing, full pallet transfer and accumulation conveyors.
• Variable pattern placement programming handles various stack patterns.
• Every system meets or exceeds RIA and ANSI safety requirements.

Case Palletizing

We palletize an almost endless multitude of different sizes, shapes, and weights of cases.
Can you stack

• Corrugated cases
• Split-top cases
• Plastic cases/cartons
• Metal cases/cartons?

We can!
As the leading experts in case palletizing, we design highly flexible, customized solutions using cutting-edge robotic and vision technologies.
Need us to pick

• One box
• Two boxes
• Three boxes
• Full row
• Full Layer
• Depalletize
• Multiple case orientations
• Or do something custom

You got it!

Interested in implementing or just discussing a robotic case palletizer for your facility?

Can/Pail/Barrel/Drum Palletizing

Palletizing cylinders for a variety of industries like paint & chemical, medical, building & construction, and others calls for specific, yet flexible design options. MCRI can design a system that will handle different products by designing custom end of arm tooling, so changeover between drum sizes or load patterns can be easily accomplished by either the operator or through the design of this tooling.

Soontrue contains other products and information you need, so please check it out.

Many times filled drums or pails can be heavy and having a robot do the heavy lifting will lower on-the-job injuries related to manual palletizing. The robot’s smooth and consistent movements will also help to improve quality and production rates.

Interested in implementing or just discussing a robotic bag palletizer for your facility?

Plastic Palletizing

Robot systems for plastic palletizing must be not only flexible but allow for quick changeover. MCRI knows the plastics & container industry is dynamic with line changeovers every time product orders are filled (can be dozens a day) and demand varies to meet end consumer needs for varying sizes in product selection.
Robotics adds a high amount of reliability, flexibility, and even mobility to these applications by:

• Eliminating the manual process of picking and packing plastic bottles
• Improving worker safety by decreasing repetitive motion injuries.
• Reducing cost by simplifying the process and changeovers.
• Allowing for the ability to better plan for product accumulation.
• Increasing quality with more consistent controls of packing bottles.
• Making it easy for the operator to program new products.
• Automating other process such as descrambling/picking, transporting, case packing, and removing bottles from blow molding machines

Motion Controls Robotics understands the process requirements from working with various companies in the industry.

Interested in implementing or just discussing a robotic warehouse palletizing for your facility?

Roll Palletizing

Rolls come in all sizes and weights and are typically a softer product that needs more careful handling than some of the other products we palletize. Rolls can be removed from winding/slitting operations or upstream packaging operations and palletized with the eye in a vertical or horizontal orientation. The system can be designed with an out-feed conveyor for sorting, quality, or product tracking.

MCRI builds custom end of arm tooling to push the slit rolls from the slitting mandrel, pick the roll by its inner diameter (ID), and then palletize the product in a variety of patterns to meet order requirements.

Shrink wrappers can be added to secure the rolls when pallets are moved out of the cell.

If you are looking for more details, kindly visit Robot stacking system.