7 Steps to Automate Case Packing with a Robotic Cell

Understand the product and production flows in detail

The starting point for any automated case packing cell project is the product itself. The specification should be built around its characteristics: primary packaging type, product shape, weight, resistance to compression and stacking, and possible transport orientations such as flat, upright or loose.

Current and target production flows also need to be assessed, including required throughput and the minimum and maximum number of products expected in each case.

An on-site audit can be carried out with the manufacturer and integrator to understand these constraints under real production conditions.

Read more: JYGA case packing machines

Define the functions expected from the packaging

The next step in a case packing automation project is to consider the packaging itself:

• How will the products be transported?

• Are multiple formats likely to need handling?

• Does the packaging need to provide functions beyond product protection?

1. presentation of products in store, for example shelf-ready trays?
2. direct handling by the final customer, for example a carrying handle?
3. natural ventilation of the product, for example open trays?

The answers will influence the choice of packaging and may affect the type of automatic case packing cell to be installed.

Selecting the right packaging is a collaborative process between the customer, the corrugated packaging supplier and the machine designer.

Study, propose and optimise the case packing cell

At this stage, JYGA, as a manufacturer and integrator of automatic case packing cells, can make initial recommendations on the technologies and machine types to use. 

Depending on the application, it may be necessary to adapt the packaging and packing strategy — including product grouping and stacking organisation — or to keep the existing packaging and adapt the machine accordingly. 

Three main families of secondary packaging are commonly used for case packing:

• RSC cases: a straightforward format supplied folded and pre-glued flat. The machine erects the case, fills it automatically by robot or conveyor, and closes it using hot-melt adhesive or tape. Discover our automatic RSC case packer
• Trays: generally open at the top, providing easy top access. The flat cardboard blank is loaded into the machine and formed automatically.
• Wrap-around cases: an increasingly common packaging family. Flat blanks are loaded into the magazine of the robotic case packer; the products are loaded and the case is then formed and closed around them. This facilitates loading and can optimise cardboard use. Wrap-around packaging can be open or closed.

Each of these families can be adapted into variants such as shelf-ready cases, two-piece cases with lids, reinforced cases or partitioned cases.

By entrusting the analysis and study to an automatic case packing specialist such as JYGA, manufacturers can potentially make savings in several areas:

• the amount of cardboard used,
• the number of blanks or cases supplied per pallet,
• the number of packed cases stacked on each pallet at the end of the line,
• operator time released for other tasks.

Note: the integrator’s study for an automatic case packing cell must take account of all HSE, risk-management and machine/operator safety requirements. Involving the operators who will use the equipment from the beginning of the project is therefore essential.

Further reading: Main occupational risks in the packaging industry

Choose the right layout for the case packing cell

Once the key requirements of the automatic case packing project have been defined, the ideal cell layout needs to be established.

The layout should take account of:

• finished-product flows from one or more lines,
• the supply of consumables such as cases and labels,
• routes used by handling equipment such as pallet trucks and forklift trucks,
• upstream and downstream storage areas,
• operator circulation,
• technician access,
• wired or wireless communication with other machines and supervisory systems.

Define the right technical solution

The final technical solution can then be defined in detail. JYGA considers all of the points above — key functions, format variety, throughput, cost and integration of complementary equipment such as palletisers, laser marking, labelling and industrial vision systems — to create a tailored solution based on proven functional modules.

JYGA also incorporates the following constraints into the design of its case packing cells:

• accessibility,
• cleaning,
• ergonomics,
• safety,
• communication.

All of these points are essential for reliable day-to-day use by production teams.

Budget and lead time for an automated case packing cell

The typical lead time for putting an automated case packing cell into production is around seven to ten months. At JYGA, this generally covers the period from the pre-project phase through to final customer acceptance and production ramp-up.

It is difficult to give a single budget because project constraints vary considerably. However, JYGA customers commonly assess return on investment over a period of around two to three years, depending on the application.

Long-term support

With more than 30 years of experience designing and installing end-of-line case packing cells, JYGA has developed a comprehensive support approach from the earliest study phases through the operating life of the equipment. 

This includes:

• involving operators from the beginning of the project so that day-to-day production constraints are understood,
• complete virtual machine design, which can also be viewed in virtual reality to help teams visualise the future installation,
• operator and technician training to provide the required level of autonomy,
• working with specialist corrugated packaging suppliers to identify the best technical case packing solutions,
• after-sales support including on-site assistance, training, remote support and spare parts.

JYGA has extensive experience working with major manufacturers in the food and beverage, healthcare, cosmetics and personal-care industries. If you are considering an automatic case packing project or want to assess the potential impact on your production, get in touch with our team.