Automated Packaging Systems Designed to Meet Your Unique Needs
Should we use automation? How much of the packaging line should we automate?
Automation affords several major benefits for packaging manufacturers. It reduces operational costs by lowering labor costs and minimizing waste from human interaction, increases throughput and productivity, and creates a safer work environment by replacing repetitive and strenuous manual jobs.
When it comes to automation, we offer fully integrated lines, from product to pallet. Producers moving from a manual process to automation often are experiencing a mismatch between production speed or volume requirements versus the limitations and costs of manual loading efforts. We can help walk you through the key considerations involving the automation of a packaging process; from primary packaging of the product itself to secondary packaging, palletizing, and tote/basket management.
We also offer ancillary automation commonly used in the packing process, like checkweigher machines, labeling machines, vision systems and inspection systems are common equipment included in automated packaging lines.
Don’t see what you’re looking for? Download our Automation eBook for a comprehensive breakdown of all our solutions below.
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Automated Feeding
A critical first step in any automated packing process is the loading of the product to the primary packaging equipment. The feeding/loading strategy will be decided by three primary attributes: production requirements, state/nature of the product being packaged, and the product presentation for the packaging process.
Automatic Loading
Automated packaging infeeds and outfeeds are designed to manage sorting, orientating, allocating, positioning and inserting products in a quick and safe manner without damaging the product. In the food industry, sanitary/hygienic design is a critical aspect of the loading process.
Secondary Packaging
Secondary packaging protects the product’s primary packaging in-transit and may be the first thing a customer sees as a retail shelf presentation. Case formers, sealers and label applicators offer a faster, more accurate and reliable approach to manual efforts. Secondary packaging automation emphasizes equipment flexibility and strong product control, and provides the ability to allow for quick and easy size changeovers of the packaging machinery.
Automated Palletizing
Palletizing packaging is used to improve the transportation of products in bulk from producers to retail or storage & distribution centers. It provides protection during shipping and storage, allowing more inventory to be moved with easier handling. Shipping and storage environments can be harsh, so tertiary packaging is aimed at optimizing footprint and in-transit protection.
Robotics
One of the most noteworthy advancements in packaging automation has involved robotics for pick and place applications. Advancements in robotics are making it easier to replicate the dexterity and vision once only available through human labor. Vision-assisted robots can pick and place products precisely using improved grippers for delicate products.
Centralized Line Control
Our fully automated packaging lines come complete with an Allen Bradley centralized control system. This system manages the interface between each piece of equipment and includes both line and safety functions. The safety system will be made up of emergency stop pushbuttons, safety cables and interlock sensors on all doors. All safety alarms and notifications will be available through the Allen Bradley Panelview HMI.
Tote/Basket Management
Reusable Plastic Containers (RPCs), also known as “totes” – or in the bakery industry, “baskets” – are made to accommodate the transfer of a wide range of products and primary packaging types. Reusable plastic totes not only reduce carbon emissions, waste, and natural resource consumption, they offer improved product protection versus cardboard alternatives.
Looking to learn more? Get a comprehensive breakdown of automation with our eBook:
Integrated Lines
GCP100 and GCP200 Gravity Case Packers
A Simplified, Flexible Approach to Automated EOL Case Packing
Request a Quote
MAIN BENEFITS
- Applicable for bagged products (bread, chicken wings, grated cheese, etc.)
- Products can be case packed into RSCs or RPCs
- Up to 60 boxes per minute
- Available with full Rockwell controls and components
- Supports multi-SKU operations
Auto Loading of Thermoformer / Tray Sealer
Product loading into a Thermoformer and Tray Sealing machine is from above into the defined cavities. There is a defined loading area, in a thermoforming machine between the forming and sealing devices, and in a tray sealing machine, between the tray denesting and sealing units.
Request a Quote
Loading and Aligning System with Robot
- The product loading into a thermoforming and Tray Sealing machine is from above into the defined cavities.
- There is a defined loading area, in a thermoforming machine between the forming and sealing devices and in a tray sealing machine between the tray denesting and sealing units.
- The products are transported with belts where the ULMA robots pick them, supported by a vision system or other detection system to define the correct position of the products.
Loading System with Robot
- The product loading system is carried out by ULMA robots. Depending on the application, it could be done in a static way with the ULMA U10H robot for organized products, and manipulating in tracking with the ULMA D12H robot for high speed applications.
- The products are detected by vision systems, photocells or other types of sensors, depending on the requirements.
- The gripping unit is specifically designed for each product to be manipulated.
Product Unloading System with ULMA U10H Robot for Product Aligning
- The unloading of the product at the exit of the thermoforming machine is done by the ULMA U10H 2 axis robot.
- This application is necessary with shaped products that avoid the mechanical aligning system with belts.
- The gripping tool is specifically designed for each product to be manipulated.
Crate Ready Systems
Depending on the crate delivery and product transport requirement, there are different concepts defined for crate packing. The requirements are related to the customer needs and to space availability.
Request a Quote
Crate Packing with ULMA U10H Robot
- Symmetrical pattern configuration crate packing
- Reduced space
- High speed
- Easy maintenance and programming
Crate Packing with ULMA D12H Robot
- Different mosaic crate packing, total flexibility
- Reduced space
- High speed manipulation
- Easy maintenance and programming
Linear LN – crate and product feeding from the same side. The crate feeding could be made in different heights, with the possibility to descend with a lift.
In U – The empty crate feeding and the exit of the complete one is made from the same side.
In L – Similar to the linear one, with the difference that the empty crate entrance is off.
Crate De-Stacking System
- This system delivers crates in singles starting from stacks or columns.
- There is a pneumatic version and a servo-driven solution depending the speed requirement.
- The crates to be de-stacked could have different shapes, dimensions or materials, detachable base or solid made.
- For better ergonomics, the de-stacking system could have a lift system from the pallet height on the floor, or alternatively from a higher level going down.
- For higher autonomy the crate piles could accumulated in a buffer system to be fed automatically to the de-stacking system.
Crate Stacking System
- This system stacks single crates.
- There is a pneumatic version and a servo driven solution depending the speed requirement.
- The crates to be de-stacked could have different shapes, dimensions or materials, detachable base or solid made.
- For better ergonomics, the de-stacking system could have a lift system from the pallet height on the floor or from a high level going down.
- A specific crate uses a bale arm system to allow the empty crates to stack inside each other and reduce the height of a complete column of empty crates.
- Those crates have some side supports called bale arms which need to be closed when stacking full crates.
- The bale arm closer has a set of closing arms which moves intermittently as the crate moves into the machine.
- This motion moves the bale arms from the open position to the closed position.
- The servo system allows for more than one closed position which may be required depending on the depth of the crate and the crate fill height.
Complete Automation Solution of Vertical Line
In a vertical wrapping line, the product is received randomly and is introduced in an inclined transport system up to the multihead weigher. This feeding system makes de-dosifying and weighing of the product to be wrapped in the vertical machine. The automation of the line is made with different processing and dosifying units, depending on the application and required production goals.
Request a Quote
Vertical Pouch Automatic Wrapping Line
The crate packing system is composed by a compact ULMA D12H robot and a product detection system (vision system, photocells etc ) to pick and place the pouches transported in a random way.
The gripping tool is specifically designed for pouches, picking them from the transport system in tracking and place inside the empty crate previously positioned.
The work range would be Ø800 mm or Ø1200mm. This type of robot is specifically designed for high speed movements with precision and small loads.
Complete Solution of Thermoforming Line
Double wrapping Thermoforming line with plastic crate and carton case loading culminating in only one palletizing system.
Request a Quote
Line 1
- Thermoforming loading with ULMA D12H robot
- Wrapped product aligning system with ULMA U10H robot
- Check weigher and metal detector system
- Empty plastic crate delivery system
- Crate packing system with ULMA D12H robot
- Bale Arm closer
Line 2
- Thermoforming loading with ULMA D12H robot
- Mechanical aligning system of wrapped products
- Check weigher and metal detector system
- Carton case erector machine
- Case packing with ULMA D12H robot
- Carton case closing machine
Palletizing
- Simultaneously palletizing of plastic crate and carton case
- Automatic empty pallet delivery
- Complete pallet wrapping and exit system
- Carton case closing machine
Complete Solution of Flow Pack Line
Automatic wrapping in Flow Pack lines with automatic feeding to cartoneer, crate packing and palletizing.
Request a Quote
Automatic Feeding System to Cartoneer
- Accumulation and control system of wrapped product
- Loading system with ULMA D12H robot
- Side cartoneer system of wrapped product group
Flow Pack Wrapping System
- Product belt distribution to several lines
- Automatic in line feeding system of the product
- Unitary wrapping of the product in Flow Pack
Crate Packing and Palletizing
- Case accumulation and loading system
- Case group wrap around system
- Palletizing and pallet wrapping system with finished pallet labeling and pallet removal
Automatic Loading to Flow Pack
Request a Quote
Compact robot cells for product loading applications which are specially designed for integration with horizontal wrapping machines. The robot gripping tools are specifically designed for each application. The speed capacity of each cell varies according to the product dimension, characteristics and flow, as well as specific requirements of the system. The work range of the robot can be adapted to the cell configuration. Each cell has its own control, however this can be included within the Flow Pack control platform. It is also possible to integrate through the robot cell all other parts of the line depending on the functionality required.
FEED PACKER
Group of Loading Robot Cells
Composed of ULMA D12H robots with vision systems to detect the products which are transported in a random way through a transport system.
The picking and placing is made dynamically in tracking, from the transport system to the wrapping machine infeed conveyor.
Product Feeding System
Product transport system in a random way. The speed of this system is controlled by the loading cell.
MULTIPACKER
Wrapped Product Transport System
The products might be transported in single file and pre-orientated. In which case we can group the products in a multiple format before manipulation.
Loading Robot Cell
Includes one or more ULMA D12H robots with a product detection system to pick a group of products for manipulation into cartons or for further wrapping. The picking and placing can be done by tracking the singles or multiple groups.
Grouping Chain System
One or two independent motor systems, creates groups of products in a continuous way to allow the robot to pick groups of products in each robot cycle.
The products might be transported, orientated and controlled to create groups in line or at 90º to the direction of travel. This process can be carried out at high speed allowing for high volume throughputs.
ULMA Robots
The sectors shown represent the areas in which the Automation division is concentrated. These markets are also represented by the Packaging division and as such the experience is complimentary to both the packaging machine and the surrounding automation.
Request a Quote
ULMA U10H Robot
2 axis robot
- Workrange 1000 mm.
- Loading, unloading and crate packing robot solution.
- Static product manipulation or defined configurations.
- Easy programming and little maintenance.
- Frame structure to absorb movements of different product weight manipulations.
ULMA D12H
3 and 4 axis robot
- Workrange Ø800 or Ø1200 mm.
- Robot for high speed applications.
- Dynamic product manipulation, possibility to create different formats with different placing configurations.
- Easy programming and little maintenance.
- Frame structure to absorb movements of different product weight manipulations.
Automation with Carton Case
Case packing line with ULMA D12H robot with carton case erector and closing machines with hot melt.
Request a Quote
Top Loader
An automatic case erector machine creates an American preformed type case, or flat carton hot melted cases and delivers it to the case packing area.
The case packing robot manipulates the products, picking them from the transport accumulation system, helped by vision or any other detection system.
The case closing machine closes the cases with adhesive tape or hot melt.
Wrap Around
Products arriving from the wrapping line are collated and grouped through a grouping chain device.
The product group is introduced onto a flat carton or case which has been indexed from the magazine.
Once the product group has been located on the case blank, the same blank is further indexed through the machine, folding the blank along the way and creating the wrapping of the product group with hot melt.
Robots and mechanical systems are used for the product group manipulation.
Side Loading
In this situation the pre-collated wrapped products are transported to the manipulator and are pushed into the side of the case. The case or carton has been folded into a complete position on four sides before manipulation. The whole group is transported to the side loading position and inserted.
Once the product group has been inserted, the case is further indexed to be closed on the front loading area.
The adhesive tape closing station closes both side of the carton case, turning and positioning before sending it to the palletizing area.
Palletizing Systems
This system is used when product versatility is required and the required production of each product is not high speed. The buffer systems optimizes the palletizing equipment, working with robots or mechanical palletizers. The criteria for selecting an optimum palletizing system depends on the needs of the project for each customer. Two palletizing systems are proposed: palletizing with robot or mechanical palletizing.
Request a Quote
Mechanical Palletizing
This machine is particularly suitable for heavy load and high speed applications with one or two different types of cases or crates. The unit is capable of speeds up to 200 cycles/h. The application focuses on different types of crates. The units can be constructed in stainless steel or in galvanized construction materials ensuring long life quality of materials.
It’s easy to change the palletizing format, with the flexibility to create different mosaics.
The crate accumulation before positioning on the pallet is done with some lateral pushers and roller transport. The gripping tool creates a lateral controlled pressure to avoid any damage to the crate and to the product inside the crate.
Different types, dimensions or material crates, detachable base or carton made could be palletized. The specific gripping tool proposal can create different types of pallet formats as required by the customer. Empty gaps between crates for aeration can also be created using this type of machine.
Robotic Palletizing
The robotic palletizing system is designed to collect crates from different packaging lines simultaneously.
It’s a very flexible system allowing the creation of pallets with different products, crates and mosaics from different production lines, simultaneously.
The gripping tool is designed specifically for each application.
The products are picked from an accumulation system to complete the cycle and positioned onto the pallet.
Thermoforming Loading and Plastic Crate Packing Line
Crate packing system integrated in wrapping lines.
Request a Quote
Loading and Aligning System with Robot
Crate Packing System
GCP100 and GCP200 Gravity Case Packers
A Simplified, Flexible Approach to Automated EOL Case Packing
Request a Quote
MAIN BENEFITS
- Applicable for bagged products (bread, chicken wings, grated cheese, etc.)
- Products can be case packed into RSCs or RPCs
- Up to 60 boxes per minute
- Available with full Rockwell controls and components
- Supports multi-SKU operations
Auto Loading of Thermoformer / Tray Sealer
Product loading into a Thermoformer and Tray Sealing machine is from above into the defined cavities. There is a defined loading area, in a thermoforming machine between the forming and sealing devices, and in a tray sealing machine, between the tray denesting and sealing units.
Request a Quote
Loading and Aligning System with Robot
- The product loading into a thermoforming and Tray Sealing machine is from above into the defined cavities.
- There is a defined loading area, in a thermoforming machine between the forming and sealing devices and in a tray sealing machine between the tray denesting and sealing units.
- The products are transported with belts where the ULMA robots pick them, supported by a vision system or other detection system to define the correct position of the products.
Loading System with Robot
- The product loading system is carried out by ULMA robots. Depending on the application, it could be done in a static way with the ULMA U10H robot for organized products, and manipulating in tracking with the ULMA D12H robot for high speed applications.
- The products are detected by vision systems, photocells or other types of sensors, depending on the requirements.
- The gripping unit is specifically designed for each product to be manipulated.
Product Unloading System with ULMA U10H Robot for Product Aligning
- The unloading of the product at the exit of the thermoforming machine is done by the ULMA U10H 2 axis robot.
- This application is necessary with shaped products that avoid the mechanical aligning system with belts.
- The gripping tool is specifically designed for each product to be manipulated.
Crate Ready Systems
Depending on the crate delivery and product transport requirement, there are different concepts defined for crate packing. The requirements are related to the customer needs and to space availability.
Request a Quote
Crate Packing with ULMA U10H Robot
- Symmetrical pattern configuration crate packing
- Reduced space
- High speed
- Easy maintenance and programming
Crate Packing with ULMA D12H Robot
- Different mosaic crate packing, total flexibility
- Reduced space
- High speed manipulation
- Easy maintenance and programming
Linear LN – crate and product feeding from the same side. The crate feeding could be made in different heights, with the possibility to descend with a lift.
In U – The empty crate feeding and the exit of the complete one is made from the same side.
In L – Similar to the linear one, with the difference that the empty crate entrance is off.
Crate De-Stacking System
- This system delivers crates in singles starting from stacks or columns.
- There is a pneumatic version and a servo-driven solution depending the speed requirement.
- The crates to be de-stacked could have different shapes, dimensions or materials, detachable base or solid made.
- For better ergonomics, the de-stacking system could have a lift system from the pallet height on the floor, or alternatively from a higher level going down.
- For higher autonomy the crate piles could accumulated in a buffer system to be fed automatically to the de-stacking system.
Crate Stacking System
- This system stacks single crates.
- There is a pneumatic version and a servo driven solution depending the speed requirement.
- The crates to be de-stacked could have different shapes, dimensions or materials, detachable base or solid made.
- For better ergonomics, the de-stacking system could have a lift system from the pallet height on the floor or from a high level going down.
- A specific crate uses a bale arm system to allow the empty crates to stack inside each other and reduce the height of a complete column of empty crates.
- Those crates have some side supports called bale arms which need to be closed when stacking full crates.
- The bale arm closer has a set of closing arms which moves intermittently as the crate moves into the machine.
- This motion moves the bale arms from the open position to the closed position.
- The servo system allows for more than one closed position which may be required depending on the depth of the crate and the crate fill height.
Complete Automation Solution of Vertical Line
In a vertical wrapping line, the product is received randomly and is introduced in an inclined transport system up to the multihead weigher. This feeding system makes de-dosifying and weighing of the product to be wrapped in the vertical machine. The automation of the line is made with different processing and dosifying units, depending on the application and required production goals.
Request a Quote
Vertical Pouch Automatic Wrapping Line
The crate packing system is composed by a compact ULMA D12H robot and a product detection system (vision system, photocells etc ) to pick and place the pouches transported in a random way.
The gripping tool is specifically designed for pouches, picking them from the transport system in tracking and place inside the empty crate previously positioned.
The work range would be Ø800 mm or Ø1200mm. This type of robot is specifically designed for high speed movements with precision and small loads.
Complete Solution of Thermoforming Line
Double wrapping Thermoforming line with plastic crate and carton case loading culminating in only one palletizing system.
Request a Quote
Line 1
- Thermoforming loading with ULMA D12H robot
- Wrapped product aligning system with ULMA U10H robot
- Check weigher and metal detector system
- Empty plastic crate delivery system
- Crate packing system with ULMA D12H robot
- Bale Arm closer
Line 2
- Thermoforming loading with ULMA D12H robot
- Mechanical aligning system of wrapped products
- Check weigher and metal detector system
- Carton case erector machine
- Case packing with ULMA D12H robot
- Carton case closing machine
Palletizing
- Simultaneously palletizing of plastic crate and carton case
- Automatic empty pallet delivery
- Complete pallet wrapping and exit system
- Carton case closing machine
Complete Solution of Flow Pack Line
Automatic wrapping in Flow Pack lines with automatic feeding to cartoneer, crate packing and palletizing.
Request a Quote
Automatic Feeding System to Cartoneer
- Accumulation and control system of wrapped product
- Loading system with ULMA D12H robot
- Side cartoneer system of wrapped product group
Flow Pack Wrapping System
- Product belt distribution to several lines
- Automatic in line feeding system of the product
- Unitary wrapping of the product in Flow Pack
Crate Packing and Palletizing
- Case accumulation and loading system
- Case group wrap around system
- Palletizing and pallet wrapping system with finished pallet labeling and pallet removal
Automatic Loading to Flow Pack
Request a Quote
Compact robot cells for product loading applications which are specially designed for integration with horizontal wrapping machines. The robot gripping tools are specifically designed for each application. The speed capacity of each cell varies according to the product dimension, characteristics and flow, as well as specific requirements of the system. The work range of the robot can be adapted to the cell configuration. Each cell has its own control, however this can be included within the Flow Pack control platform. It is also possible to integrate through the robot cell all other parts of the line depending on the functionality required.
FEED PACKER
Group of Loading Robot Cells
Composed of ULMA D12H robots with vision systems to detect the products which are transported in a random way through a transport system.
The picking and placing is made dynamically in tracking, from the transport system to the wrapping machine infeed conveyor.
Product Feeding System
Product transport system in a random way. The speed of this system is controlled by the loading cell.
MULTIPACKER
Wrapped Product Transport System
The products might be transported in single file and pre-orientated. In which case we can group the products in a multiple format before manipulation.
Loading Robot Cell
Includes one or more ULMA D12H robots with a product detection system to pick a group of products for manipulation into cartons or for further wrapping. The picking and placing can be done by tracking the singles or multiple groups.
Grouping Chain System
One or two independent motor systems, creates groups of products in a continuous way to allow the robot to pick groups of products in each robot cycle.
The products might be transported, orientated and controlled to create groups in line or at 90º to the direction of travel. This process can be carried out at high speed allowing for high volume throughputs.
ULMA Robots
The sectors shown represent the areas in which the Automation division is concentrated. These markets are also represented by the Packaging division and as such the experience is complimentary to both the packaging machine and the surrounding automation.
Request a Quote
ULMA U10H Robot
2 axis robot
- Workrange 1000 mm.
- Loading, unloading and crate packing robot solution.
- Static product manipulation or defined configurations.
- Easy programming and little maintenance.
- Frame structure to absorb movements of different product weight manipulations.
ULMA D12H
3 and 4 axis robot
- Workrange Ø800 or Ø1200 mm.
- Robot for high speed applications.
- Dynamic product manipulation, possibility to create different formats with different placing configurations.
- Easy programming and little maintenance.
- Frame structure to absorb movements of different product weight manipulations.
Automation with Carton Case
Case packing line with ULMA D12H robot with carton case erector and closing machines with hot melt.
Request a Quote
Top Loader
An automatic case erector machine creates an American preformed type case, or flat carton hot melted cases and delivers it to the case packing area.
The case packing robot manipulates the products, picking them from the transport accumulation system, helped by vision or any other detection system.
The case closing machine closes the cases with adhesive tape or hot melt.
Wrap Around
Products arriving from the wrapping line are collated and grouped through a grouping chain device.
The product group is introduced onto a flat carton or case which has been indexed from the magazine.
Once the product group has been located on the case blank, the same blank is further indexed through the machine, folding the blank along the way and creating the wrapping of the product group with hot melt.
Robots and mechanical systems are used for the product group manipulation.
Side Loading
In this situation the pre-collated wrapped products are transported to the manipulator and are pushed into the side of the case. The case or carton has been folded into a complete position on four sides before manipulation. The whole group is transported to the side loading position and inserted.
Once the product group has been inserted, the case is further indexed to be closed on the front loading area.
The adhesive tape closing station closes both side of the carton case, turning and positioning before sending it to the palletizing area.
Palletizing Systems
This system is used when product versatility is required and the required production of each product is not high speed. The buffer systems optimizes the palletizing equipment, working with robots or mechanical palletizers. The criteria for selecting an optimum palletizing system depends on the needs of the project for each customer. Two palletizing systems are proposed: palletizing with robot or mechanical palletizing.
Request a Quote
Mechanical Palletizing
This machine is particularly suitable for heavy load and high speed applications with one or two different types of cases or crates. The unit is capable of speeds up to 200 cycles/h. The application focuses on different types of crates. The units can be constructed in stainless steel or in galvanized construction materials ensuring long life quality of materials.
It’s easy to change the palletizing format, with the flexibility to create different mosaics.
The crate accumulation before positioning on the pallet is done with some lateral pushers and roller transport. The gripping tool creates a lateral controlled pressure to avoid any damage to the crate and to the product inside the crate.
Different types, dimensions or material crates, detachable base or carton made could be palletized. The specific gripping tool proposal can create different types of pallet formats as required by the customer. Empty gaps between crates for aeration can also be created using this type of machine.
Robotic Palletizing
The robotic palletizing system is designed to collect crates from different packaging lines simultaneously.
It’s a very flexible system allowing the creation of pallets with different products, crates and mosaics from different production lines, simultaneously.
The gripping tool is designed specifically for each application.
The products are picked from an accumulation system to complete the cycle and positioned onto the pallet.
Thermoforming Loading and Plastic Crate Packing Line
Crate packing system integrated in wrapping lines.
Request a Quote
Loading and Aligning System with Robot
Crate Packing System
