Robotic depalletizing solution increases filling-line capacity by 50%
A global personal care manufacturer improved filling-line throughput, OEE, and production resilience by stabilizing upstream product flow with an integrated automation solution from FlexLink.
To meet rising production demands, the manufacturer needed to increase filling-line capacity, improve OEE, and stabilize upstream container flow without expanding its production footprint. FlexLink delivered an integrated robotic depalletizing solution combining robotics, conveyors, product handling, inspection, and line integration. The result was a 50% increase in filling-line capacity, improved operational reliability, and greater flexibility for future production demands.
Smarter container flow for Personal Care manufacturing
The manufacturer operates high-volume personal care production lines where container availability, format flexibility, and packaging quality directly affect filling performance. Products are supplied in various glass and plastic jar formats, requiring stable handling, controlled orientation, and reliable flow into two filling lines located on the first floor of the production facility.
In personal care manufacturing, frequent SKU variation, premium packaging appearance, and dense production layouts make upstream product flow a critical performance factor. The new system therefore needed to reliably process multiple jar formats, protect container quality, integrate with existing equipment, and meet strict structural and environmental requirements.
Rather than automating an isolated process step, the manufacturer needed a complete upstream packaging-flow solution that could keep the fillers supplied, reduce manual intervention, and support future production growth.
The challenge: robotic depalletizing for high-volume filling-line performance
The depalletizing operation represented a critical link between warehouse logistics and filling-line performance. Any interruption, misalignment, or product-handling issue could affect downstream productivity.
Key challenges included:
- Processing multiple glass and plastic jar formats without product damage or changeover-related disruptions
- Installing a high-capacity automated solution on the first floor while complying with building load restrictions
- Reducing operational noise levels within the production environment
- Ensuring jars reached the filling lines in the correct orientation and condition
- Maintaining production continuity during maintenance activities and smaller production runs
The manufacturer needed more than a robotic depalletizer. It required an integrated production-flow solution capable of delivering a continuous, controlled, and reliable supply of containers from pallet to filler while protecting quality and line availability.
Integrated robotic depalletizing and conveyor solution for packaging flow
FlexLink was selected for its ability to combine robotics, conveyor technology, product handling, inspection, and line integration into one coordinated automation solution.
The system was built around two Güdel gantry robots equipped with multifunction vacuum grippers capable of handling entire layers of jars as well as slip sheets. The solution was engineered to accommodate multiple packaging formats, including both glass and plastic containers.
To overcome the facility's first-floor installation constraints, FlexLink developed a structural design that distributed operational loads through the building's ceiling structure. This approach enabled the installation of a high-capacity depalletizing system while meeting the facility's structural requirements.
To ensure a smooth and uninterrupted flow of products to the filling lines, FlexLink integrated several complementary technologies into the solution:
- Automated pallet conveyor system
- Layer handling and slip-sheet removal
- Product alignment table converting mass flow into single-lane flow
- Automatic jar inspection system
- Reject functionality for fallen or incorrectly positioned jars
- Acoustic enclosures for noise reduction
- Integration with existing blowing equipment
- Seamless connection to both filling lines
Together, these technologies reduced interface complexity, minimized manual intervention, and supported stable, efficient, and scalable filling-line operation.
Results: higher filling-line capacity, improved OEE, and production flexibility
50% increase in filling-line production capacity
The most significant outcome was a 50% increase in filling-line capacity. By automating the depalletizing process and optimizing product flow, the manufacturer significantly increased the volume of jars delivered to the filling lines, creating additional production capacity without expanding its footprint.
Improved OEE through automated jar inspection and quality control
The integrated inspection system plays a critical role in maintaining line performance.
By automatically detecting and removing fallen or incorrectly positioned jars before they reach the fillers, the system reduces disruptions, minimizes manual intervention, and helps prevent downstream stoppages. This proactive quality-control approach contributes directly to improved Overall Equipment Effectiveness and more reliable production performance.
Enhanced production flexibility for changing packaging demands
Production environments must often accommodate maintenance activities, short production runs, and changing market demands.
To support this flexibility, FlexLink incorporated a manual bypass solution that enables production to continue during depalletizer servicing or when smaller production batches are being processed. This capability helps maintain productivity while increasing operational resilience.
Reduced noise levels in high-volume production environments
The installation also included acoustic protection features designed to reduce operational noise without affecting system performance. The result is a more controlled production environment that supports both efficiency and workplace comfort.
See FlexLink’s automation in action:
Beyond robotic depalletizing: improving end-to-end production performance
While the project began as an initiative to automate pallet handling, the final solution delivered value across the entire production process.
By combining robotics, inspection technology, product-flow management, structural engineering expertise, and seamless line integration, FlexLink addressed multiple operational challenges with a single coordinated solution. The result was not only higher throughput, but also improved reliability, protected product quality, stronger operational flexibility, and better use of available factory space.
For manufacturers in personal care, cosmetics, food, beverage, pharmaceutical, and other consumer goods industries, the project demonstrates how integrated automation can stabilize critical packaging flows, improve line availability, support format variation, and create measurable performance gains beyond the automation of a single process step.
Ready to improve filling-line performance?
FlexLink's robotic depalletizing and integrated production-flow solutions help manufacturers increase throughput, reduce downtime, protect product quality, and make better use of existing factory space.
Contact FlexLink to explore how a production-flow assessment can identify opportunities to increase throughput, reduce downtime, and future-proof your automation strategy.