Piątnica strengthens dairy production with FlexLink integrated robotic automation

Customer challenge

Piątnica needed to improve efficiency across several dairy production stages while keeping operations stable in an existing production environment. The main challenges were to:

• Reduce operator involvement in manual product mixing and tray handling, especially in refrigerated areas.
• Maintain accurate and continuous product alignment before packaging.
• Expand palletizing capacity across multiple production lines.
• Increase automation while preserving production continuity and maximizing the use of existing infrastructure.

FlexLink solution

FlexLink delivered an integrated robotic automation approach covering three key applications: product mixing, vision-guided alignment, and centralized palletizing. Each solution addressed a specific production need, while together they created a more connected, efficient, reliable and scalable manufacturing operation. 

Need: Automate product mixing and tray handling in refrigerated areas | Deployed solution: Compact robotic mixing cell

For product mixing and tray handling, FlexLink implemented a compact robotic system using two Fanuc LR Mate robots, vacuum grippers, tray stackers, destackers and a closed-loop tray conveyor. The system reused trays throughout the process and relied on proven mechanical principles to keep the solution simple, robust and reliable in a refrigerated production environment. This improved operator ergonomics, reduced repetitive handling and made the mixing process more stable and predictable.  

Need: Ensure accurate product alignment before packaging | Deployed solution: Vision-guided SCARA alignment system 

For product alignment, FlexLink developed a vision-guided SCARA robot solution that transformed product flow from four lanes into three while maintaining correct orientation and continuous movement into the packaging machine. The system combined product tracking, hygienic WLX conveying, stainless-steel structures and Siemens-based controls to support reliable food-industry operation. This improved packaging flow stability, reduced disruption risk and ensured products reached the packaging machine in the correct orientation.

Need: Expand palletizing capacity across multiple production lines | Deployed solution: Centralized robotic palletizing architecture 

For palletizing, FlexLink expanded the customer’s existing system through a phased central robotic architecture serving three independent production lines. The solution included a Fanuc M-410iC six-axis robot, multifunctional layer gripper, FlexLink conveyors, buffering systems, pallet handling and Siemens controls synchronized with existing production equipment. This improved end-of-line efficiency, reduced manual palletizing work and created a scalable foundation for future production growth.

See FlexLink’s automation in action at Piątnica:

Turning automation into production value  

The automation projects delivered measurable performance improvements across the production flow. Product mixing reached up to 216 cups per minute and 18 trays per minute, while the vision-guided alignment system supported up to 45 picks per minute. The centralized palletizing solution automated palletizing at up to 55 trays per minute across three production lines.

Beyond throughput gains, Piątnica reduced repetitive manual handling, improved ergonomics in chilled production areas and increased process stability. By integrating automation with existing infrastructure, the company expanded capacity while protecting production continuity and creating a scalable foundation for future growth.

The value of integrated automation  

The Piątnica projects show how robotic automation can improve more than a single production step. By combining product handling, vision-guided alignment, conveyors, pallet logistics and controls, FlexLink helped turn separate operational challenges into one coordinated production-flow solution.

This integrated approach supports higher efficiency, better working conditions and scalable growth, while meeting the reliability and hygiene requirements of dairy manufacturing.

Ready to explore what integrated automation could do for your production? 

Learn more about FlexLink’s approach to dairy and food automation and get in touch with our experts.