One compact robot cell integrates case packing and palletizing

Introducing automation into an existing production environment can be difficult when floor space is limited, and new equipment must fit around established machinery, material routes, and pedestrian flows.

A leading food ingredients manufacturer faced this challenge when it sought to automate both case packing and palletizing in a highly constrained production area. The solution also had to integrate with existing equipment, support safe operations, and deliver consistent carton closing and gluing performance.

Working closely with the customer, FlexLink developed an integrated robotic solution that brought multiple end-of-line functions together in a single compact cell.

The challenge

Separate automation systems for case packing and palletizing would have increased the required footprint and made the layout more complex.

• The solution also needed to connect seamlessly to existing production equipment while supporting safe operations and maintaining reliable carton closing and gluing performance.
• Any solution also had to work within a brownfield environment, avoiding major facility modifications and minimizing disruption to existing production flows.

The solution

FlexLink designed a compact robotic cell measuring approximately 3.5 x 3.5 metres. At its centre, a single FANUC robot performs both case packing and palletizing. Using one robot for multiple tasks increases the use of robotic capacity, simplifies the layout, and keeps the automation footprint to a minimum.

The cell integrates the following functions:

• Product stacking
• Carton handling and forming
• Automated case packing
• Carton closing and gluing
• Pallet handling
• Robotic palletizing 

The solution includes pallet conveyors, a pallet destacker, a product stacker, a carton-format magazine, a carton closer, a gluing system, and a multifunctional gripper for carton forming and box picking. The cell fencing was adapted to the existing product cooling system to help protect product integrity throughout packaging.

Engineering for a brownfield environment

The robotic cell was integrated with the customer's existing machinery and production flows rather than requiring extensive changes to the facility. This approach preserved valuable floor space and supported safe movement of materials and personnel.

During the concept phase, FlexLink engineers also identified opportunities to improve the cardboard packaging design. The changes supported more consistent carton closing and improved process reliability, demonstrating how application engineering can create value beyond the automation equipment itself.

The results

The customer automated two critical end-of-line operations within one compact footprint. The combined solution delivered four clear areas of value:

• Space saving: Case packing and palletizing were consolidated in one approximately 3.5 x 3.5 metre cell, avoiding separate systems and preserving production floor space.
• Reduced layout complexity: One robot carries out both operations, simplifying the automation layout and increasing the use of robotic capacity.
• Reliable packaging: Integrated carton forming, closing, and gluing support consistent packaging performance, while packaging-design improvements strengthened process reliability.
• Easier brownfield integration: The cell connects with existing machinery and production flows, limiting the need for major facility modifications. 

By consolidating multiple functions into one system, the customer achieved a streamlined, reliable, and space-efficient end-of-line process without expanding the production footprint.

Creating more value from less space

This project shows how a multifunctional robotic cell can overcome footprint limitations while maintaining packaging quality and operational efficiency. For manufacturers working within existing facilities, combining case packing and palletizing can reduce manual handling, simplify layouts, and open automation opportunities without extensive plant modifications.

Explore compact End-of-Line automation

Looking to automate packaging and palletizing in an existing facility? FlexLink's integrated robotic solutions help manufacturers make better use of available space while creating efficient and reliable end-of-line production flows. Contact FlexLink now.