Modernizing heavy bag palletizing in a constrained brownfield environment

A leading global manufacturer of yeast and fermentation solutions was looking to improve efficiency and safety at the end of one of its production lines. The facility relied on manual handling of heavy 25 kg bags and operated with conveyor equipment that had been serving production for approximately two decades. 

The customer sought a solution that would not only automate palletizing but also integrate seamlessly into an existing brownfield environment with limited available space and ongoing production requirements.

The challenge

Automating heavy bag handling presents challenges beyond simply installing a robot. The customer needed to:

• Eliminate repetitive manual lifting of 25 kg bags
• Improve operator safety and ergonomics
• Fit a robotic solution into a constrained factory layout
• Integrate the new system with existing upstream machinery
• Modernize conveyor infrastructure that had been operating for around 20 years
• Maintain reliable end-of-line performance while minimizing disruption to production 

The complexity of the project required a solution capable of balancing automation, space constraints, safety requirements and long-term operational reliability.

The FlexLink solution

FlexLink designed and delivered a compact robotic palletizing cell tailored to the customer's existing production environment. 

At the heart of the solution is a Fanuc industrial robot equipped with a mechanical multifunctional gripper capable of handling three different tasks with a single tool:

• Palletizing 25 kg bags
• Handling slip sheets
• Managing empty pallets

By combining multiple handling functions into one end-of-arm tool, FlexLink helped maximize flexibility while keeping the footprint of the cell compact.

The project also included:

• Reachability and capacity analysis
• Detailed safety assessment and engineering
• Integration with the existing gluing system
• Connection to upstream production equipment
• Modernization of legacy conveyor lines
• Installation of pallet conveyor systems 

Rather than replacing only a single process step, FlexLink focused on improving the complete end-of-line flow to create a more robust and reliable operation.

Implementation in a brownfield environment

Working within an operating production facility required careful planning and engineering.

FlexLink collaborated closely with the customer to integrate the robotic palletizing cell into the existing layout while preserving production efficiency and minimizing disruption. Detailed analysis ensured that robotic reach, throughput requirements and safety considerations were addressed before installation. 

During the project, additional enhancements were introduced to improve day-to-day usability and process stability. These included automatic pallet position correction within the stack and automatic management of loose film extending from the bags. Together, these refinements helped improve pallet quality and reduce operator intervention.

The modernization of aging conveyor infrastructure further strengthened the reliability of the overall end-of-line operation.

Results

The integrated solution delivered significant operational benefits:

Improved workplace safety

The robotic system removed repetitive heavy lifting from daily operations, reducing manual handling and improving ergonomics for operators.

More reliable end-of-line performance

Automated palletizing, pallet handling and slip-sheet handling helped stabilize production flow and reduce process variability.

Extended value from existing assets

By modernizing conveyors and integrating with existing equipment, the customer was able to upgrade performance without rebuilding the entire line.

Enhanced process usability

Automatic pallet correction and film-handling functions improved process consistency and reduced the need for operator intervention.

Future-ready operation

The combination of robotics, conveyor modernization and integrated controls created a more sustainable and flexible platform for future production requirements.

See FlexLink’s automation in action:

Why it matters

Many manufacturers face the challenge of introducing automation into facilities that were not originally designed for robotics. This project demonstrates how a carefully engineered solution can modernize brownfield production environments while preserving existing investments.

By combining robotic palletizing, conveyor modernization, safety engineering and system integration, FlexLink helped transform a manual, labor-intensive end-of-line process into a safer and more dependable operation.

The result is not simply a robotic cell, but a complete production-flow improvement designed around the realities of an existing factory environment.

Looking to automate heavy bag palletizing or modernize a legacy end-of-line operation? 

FlexLink combines robotics, conveyor systems, safety engineering and production-flow expertise to deliver integrated solutions tailored to real factory constraints. Contact FlexLink today.