Whether your warehouse is small or large, there are many important considerations for efficient material handling operations. While many of these operations depend on standardization, you must also consider your employees’ capabilities. For instance, you should avoid unorganized spaces and ensure that your storage areas balance selectivity with accessibility. The principles of material handling include simple and complex equipment. There are four basic types of equipment, including cranes, forklifts, and stackers.
If you’re looking to increase the efficiency of your packaging operations, you should consider investing in a packaging robot. These sophisticated machines are easier to integrate into your workspace, making them more efficient. As an added benefit, they are also much less expensive than manual labor. First, read on to learn more about the benefits and capabilities of packaging robots. Then, decide whether a robot is a right option for your business.
Pick and Place Robots
Pick and place robots are automated systems that use motion axes to manipulate objects. Their accuracy and repeatability are crucial to manufacturing processes. In general, pick and place robots must be able to repeat actions to less than half a millimeter, so they must be highly accurate. Speed is also essential, as it will impact how fast the robot can perform its tasks and keep up with the workflow—choosing a pick and place robot that can cope with peak demand periods.
In addition to their accuracy and high-speed operations, pick and place robots are helpful in automated production environments. They can perform repetitive tasks more quickly and more accurately than human operators. This frees up human resources and allows staff to focus on more complex tasks. Pick and place robots also have the added benefit of eliminating human error. This is particularly important in warehouses and factories, where errors can cause substantial damage to products. Moreover, pick and place robots can also be designed to remove defective or damaged items from bins.
We mount the pick and place robots on a stand and can configure them to access different areas. They use sophisticated vision systems to determine which objects are best for placement. Depending on the type of application, pick and place robots can be helpful for assembly, bin picking, packaging, and other processes. Pick and place robots also use a robotic arm and sensors to enhance accuracy. This is an excellent advantage for many businesses, increasing productivity and efficiency.
Cartesian robots
The advantages and capabilities of Cartesian robots are endless. These machines have an open, spherical work envelope that is easy to visualize, which helps with safety guarding. The work area of a Cartesian robot is also wide, so there is less risk of striking an operator. By contrast, SCARA and articulated robots have cylindrical work envelopes, making it challenging to fabricate guard fencing.
Flexible
Automated warehousing is becoming increasingly common for consumer packaged goods manufacturers. This technology increases efficiency by handling material transportation, machine loading, and unloading tasks.
Mobile robots with versatile capabilities enable companies to maximize the use of their packaging lines and achieve increased production flexibility. They can move between various workstations to fulfill a range of functions. AMRs also increase flexibility by providing increased visibility and accessibility.
Easy to integrate
As the popularity of robotics continues to grow, easy-to-integrate packaging robots are making their way into end-of-line packaging operations. By automating these tasks, companies can reduce ergonomically risky human work and increase throughput and productivity.
Packaging robots can be easily integrated into the workflow and adapted to various packaging tasks. In addition, they can be mounted in multiple positions to maximize flexibility and minimize floor space.
Additionally, they are flexible enough to change their programming according to changing needs. Therefore, companies can implement them without rearranging production lines or reducing productivity.
Cost-effective
A robotic packaging line is an excellent solution to various packaging needs, from standard to bespoke. The technology can achieve high speed and low maintenance while working at high capacity for up to 70,000 hours.
As people in business become more cost-conscious about time, space, and sales, they are increasingly interested in cost-effective packaging solutions. Production line automation allows businesses to leverage ingenuity and efficiency without sacrificing the quality of workmanship.
Precision
In the pharmaceutical industry, packaging robots can be extremely helpful in eliminating damage to products in the process of packing. Their precision ensures that the product does not break during the packaging process, and they can be programmed to handle different end-of-arm tooling.
The History of Packaging Robots
If you’re interested in the history of packaging robots, read this article to learn more about these machines. In this article, we’ll talk about the first commercially available industrial robot, its design, and the costs they incur. You’ll also discover the benefits of robotic packaging machines and the challenges they face.
Evolution of packaging robots
The evolution of packaging robots has changed how we think about manufacturing automation. Historically, robots were primarily helpful for heavy-duty or hot applications. Now, they are useful in secondary, tertiary, and primary applications.
First commercially available industrial robots
In 1966, American inventor George Devol began work on a robotic arm that would transfer objects from one point to another. This robotic arm would use hydraulic actuators and program joint coordinates to perform repetitive motions.
Initially, Unimation had limited success with the robot but gained support from General Motors and other companies to develop a more advanced robot. By 1978, the company had developed two different types of industrial robots.
Costs of robotic packaging machines
The cost of a robotic packaging machine varies widely depending on the type and size of the robot. For example, off-the-shelf machines with mounted filling mechanisms cost around $75,000, while dedicated machines cost more than $250,000 and take months to arrive.
However, a robot with a vision system can cost up to $50,000. A non-robotic packaging machine can cost anywhere from two to three times as much. Today’s robots have more advanced vision systems and can process images faster and in greater detail than ever.
The benefits of robotic packaging automation include increased accuracy and reduced staff injury. It also frees staff from repetitive and dangerous tasks. In addition, robotic systems improve standardization and quality control. Cost-cutting is another key benefit. As automation costs have decreased considerably, robotic packaging machines are now available at reasonable prices.
Benefits that place robots at the front
There are numerous advantages of using packaging robots in the manufacturing industry. The versatility of these robots is a prime example. Human workers are limited to a few tasks, but robots can take on various jobs. Its slim arms and wide reach make it ideal for picking and placing products. In addition, its sturdy repeatability and precision allow it to adapt to different products quickly and efficiently.
End-effectors
In the history of packaging robots, end-effectors have been essential in helping machines perform different tasks. The types of end-effectors depend on the products’ primary and secondary packaging.
For example, one head with multiple air-controlled suction cups can pick up packaged bread or muffins from a conveyor belt and place them in preformed boxes. However, some end-effectors require special customization for the specific packaging of products.
Functionality and Growing Adoption of industrial Robots for Secondary Packaging
Using robotics for secondary packaging will be the next logical step as labor prices continue to rise in traditional LCCs. Compared to traditional LCCs, which use human workers for packaging, small and medium CPGs will benefit more from automation.
Functionality
Packaging robots can be helpful for many purposes. Besides packaging, we can use them for other functions, such as sorting and palletizing. With their versatility, they can cut down on costly errors and maintain high levels of efficiency.
Packaging robots can easily change to different actions when needed, making changeovers a breeze. Additionally, they allow line operators to change the outline of a pallet or case without manually re-packaging the products.
Industrial robots in the food and beverage industry
These grippers are specialized tools that help the robot manipulate these products. The food and beverage industry often requires packaging robots to handle slippery or wet items. Furthermore, a soft touch may not be appropriate for delicate products. An appropriate gripper is essential to make the job easier for the robot.
Programming a Pick and Place Robot
There are two basic methods of programming a pick and place robot. First, you can program your robot offline using a workstation and virtual items. The virtual items aren’t a full representation of the real world; you only need enough to complete the task.
The second method uses reference frames and four targets. The robot uses a reference frame to move between the items. After programming your robot offline, you’re ready to test the robot.
A pick and place robot typically has a long arm extending to cover a large area. The end of the arm is attached to a specialized attachment that allows it to pick a specific type of object. They can transfer items between stationary surfaces, moving surfaces, and conveyor belts. The robot’s arm consists of several segments. The first three segments of the work envelope define the distance the robot can move before picking.
First, the robot uses sensors to update its internal state estimate. Next, compare this estimate to the desired position. Then, the robot calculates the error between the actual and expected positions.
The goal is to move towards the desired location while minimizing error. It will take a few tries to reach the desired location before reaching the end. The robot will take about two weeks to reach its final destination.
Growing adoption of robotic picking in secondary packaging
Today’s biggest trends in automation in the secondary packaging industry show a clear trend toward increasing robot use. According to statistics, 85% of participants plan to expand their automation portfolios in the secondary packaging industry.
Robots are ideal for packaging applications where repetitive tasks are required to reduce labor costs while improving productivity. In addition, secondary packaging requires high precision and speed, making it an ideal fit for robotic solutions.
Increasing product complexity and shortened production runs are driving increased automation in the secondary packaging industry. According to a recent survey, 85% of CPG participants are interested in extending their automation portfolios to include secondary packaging.
