Page 58 - Food&Drink Jan-Feb 2022 magazine

TRENDS & TECHNOLOGY
Automation According to the International Federation of Robotics (IFR), the number of industrial
robots has more than tripled during the
past decade globally, steadily conquering new markets, with pick-and-place robots becoming a key automation solution and the fastest-growing robotics segment (40% market share).
Experts predict that the market for pick-and- place robots will triple within the next 10 years, due to the reliability, productivity and food safety benefits they offer. Robots are able to achieve these optimisations because they address three trends of this price-sensitive industry at once: flexibility, efficiency and quality.
HIGHER FLEXIBILITY FOR CHANGING MARKET REQUIREMENTS
With markets more fast-paced and product cycles shortening, manufacturers must continuously introduce a wide variety of products in different packaging styles and sizes to remain competitive. These frequent changes increase the pressure during production.
“Pick-and-place robots are able to increase flexibility, allowing for varying products in different formats to be packaged on one line without long downtimes. Robots with the right tool can handle even delicate products such as cookies, chips, bars or baked goods,” said Peter Pontikis, director at Nupac, Syntegon’s Australian partner.
As demand increases, the scalability of robot solutions shows their value. Food manufacturers can opt for a fully automated packaging line from the outset or alternatively, existing lines can be automated step-by-step by delegating production tasks one after another to robots. The modular concept of the robotic pick-and-place platform
(RPP) allows food manufacturers to add additional robots to their packaging line at a later stage, thus increasing their production output step-by-step.
HIGHER EFFICIENCY THROUGH SMART DIVISION OF TASKS Once pick-and-place robots have been integrated into the packaging line, they work quickly, reliably and without interruptions or fatigue. Their integration makes it possible to relieve employees of tiring tasks, such as loading carton boxes or feeding products to the line by hand, and instead can take on more complex processes and tasks such as format changes, cleaning and line supervision.
The better manufacturers succeed in optimising the division of tasks between employees and machines in their production, the greater the benefits. Supported by vision control systems, robots detect defective products during production and eject them immediately, preventing defective products from reaching the market and causing economic or image damage to the brand. At the same time, robotic solutions improve plannability, as downtimes can be scheduled flexibly. Production capacities are used optimally, especially when producing small batch sizes.
HIGH QUALITY, LOW CONTAMINATION RISK & FAST CLEANING
When it comes to quality, robots offer decisive advantages. They reduce the number of contacts between production staff and products, thus reducing the risk of contamination. Naturally, this risk is particularly high when food items are not yet wrapped into their protective primary packaging. Integrating pick-and-place robots in the handling and feeding areas proves a safe alternative.
If assortment packs are assembled, the vision system also recognises the different unsorted products on the belt. It makes sure the robots can place them in boxes or trays, according to specifications set in the HMI. These processes run automatically once they have been programmed. In addition, the robots detect defective products during production and eject them immediately.
To further reduce the risk of contamination, the robot arms are integrated in stainless steel cells whose surfaces are particularly easy to clean.
TOWARDS THE FACTORY OF THE FUTURE
Pick-and-place robots have taken on a key role in modern production environments. If manufacturers succeed in efficiently integrating these automated helpers into their new or existing packaging lines, they are equipped to meet the demands of a dynamic food market. Further developments in robotics and automation will continue to provide manufacturers with more competitive advantages in the coming years. ■
drives
quality &
efficiency
The megatrend automation has continued to shape the manufacturing industry, gathering momentum during the pandemic. As manufacturers realise the competitive advantages of automation, robots are becoming indispensable on the factory floor.
The number of robots in each robotic cell of the RPP platform can be configured individually to automate processes such as feeding, handling and loading.
6 JANUARY-FEBRUARY 2022 MACHINERY MATTERS