Smart automation in compact spaces: meet FlexLink’s Carton Loader
In today’s fast-paced manufacturing environment, the demand for smart automation in packaging is constantly growing: industries are under increasing pressure to boost efficiency, reduce manual handling, and ensure consistent quality — all while operating within tighter spatial and labor constraints. As companies in the food, home care, personal care, tissue paper and other sectors strive to modernize their end-of-line processes, intelligent and space-saving carton loading robots are becoming essential to stay competitive and meet evolving production needs.
This is where FlexLink’s know-how comes into play, delivering turn-key solutions to handle large and complex projects meeting high customer expectations.
The Robotic Carton Loader: packaging automation at its finest
FlexLink’s Carton Loader is a compact and intelligent automatic carton loading solution designed to streamline the process of depalletizing and loading flat carton bundles into case-forming machines. At the heart of the system is the collaborative robot, seamlessly integrated. This setup brings flexibility, safety, and efficiency to end-of-line packaging operations, particularly in environments where floor space is limited, while also improving safety and ergonomics.
Automatic carton loading with accurate identification and handling
The system is equipped with a vision-guided gripper, which enables accurate identification and handling of carton bundles with minimal human intervention. This vision-based approach allows for dynamic adaptation to varying bundle positions, while enhancing process reliability and reducing the need for precise manual placement. To further improve operational safety and reduce manual handling, FlexLink’s Carton Loader features an automatic strap cutting mechanism. This eliminates the need for operators to manually trim plastic straps, minimizing the risk of injury and ensuring a safer working environment.
A great fit even in small production spaces
Designed with compactness in mind, this palletizing robot operates within a minimal footprint and might not require external safety fencing or scanners. This makes it an ideal choice for facilities where space is at a premium. The collaborative nature of the robot ensures safe interaction with human operators while maintaining productivity and throughput.
Configurable options of FlexLink’s carton loading robots
Flexibility is also a key advantage of FlexLink’s carton loading robots: the design supports modular installation, with configurable options for both left- and right-handed layouts, allowing it to adapt to different production line orientations. Full integration with the case former is achieved via Ethernet communication, while format changeovers can be easily managed through the machine’s HMI (Human-Machine Interface) to ensure quick and user-friendly operation.
In addition, the system includes a dedicated discard mechanism for the safe removal of straps and interlayer materials, specifically engineered to prevent operator contact and further improve workplace safety.
FlexLink robotic palletizers: developed through proven expertise
FlexLink brings decades of experience in production logistics, with a strong focus on developing efficient layouts and compact automation solutions designed to accommodate future expansion. As a turn-key supplier, FlexLink provides not only mechanical systems but also complete integration of robotics and electrical control across the entire production line. Over the years, the company’s control engineers have established a robust set of standards — from the design of electrical cabinets and development of PLC and robot programs to the creation of intuitive, user-friendly HMIs. This integrated approach ensures seamless operation, high reliability, and ease of use across all levels of automation.
See FlexLink’s Carton Loader in action!
Innovation never stops: more from FlexLink
FlexLink expertise answers different needs. Besides the Carton Loader, the company supplies two other robotic solutions which are innovating the palletizing sector: the RC12 and the RI20.
The RC12 is a collaborative robot palletizer: it can efficiently handle payloads of up to 10 kg at a rate of up to 14 boxes per minute with a double-pick gripper. Maintaining a small footprint, it allows for flexible installation in various settings, without the need for a surrounding fence or cage. The RC12 is surprisingly simple to program: operators can create new pallet patterns or modify existing ones in under five minutes without any programming expertise, while reducing design errors and configuration times thanks to an intuitive setup.
The RI20 is an industrial palletizer, able to handle payloads up to 15kg at 12 cycles per minute, enabling continuous operations. With no mainframe attached to the flood, it is a mobile solution suitable for use in multiple production lines. Robot set-up and configuration are straightforward, thanks to the user-friendly design of the interface. The RI20 enhanced safety system creates a safe co-existence with operators. When motion is detected in the safety area, production slows down, rather than coming to a complete stop.
Enter a world of pure innovation
“At FlexLink, we believe that strong partnerships are the foundation for delivering the most advanced and reliable automation solutions. By working closely with our customers, we’re able to truly understand their challenges and design technologies that not only meet today’s needs but are ready for tomorrow’s opportunities.” - Ramon Avalos, Managing Director FlexLink Spain.
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