Automated Wrap-Around Case Packer for Butter Portions

Company

As part of a continuous improvement programme for its packaging lines, this production site specialising in dairy products was looking for an automated solution to optimise the case packing of butter rolls and portions. The aim was to replace manual operations with an installation capable of handling different product and case formats (wrap-around cases, trays with lids and shelf-ready cases), while maintaining high, consistent throughput.

The solution had to meet several requirements: receive and load the products, form the cases, pack the butter portions in layers, close the cases and discharge them at the end of the line. All of this had to be achieved in a safe, hygienic environment, with a controlled footprint suited to the industrial constraints of the dairy sector.

Project & solution

To meet the customer’s requirements, JYGA proposed the integration of a wrap-around case packer dedicated to the automatic case packing of butter portions and rolls at the outfeed of the packaging lines.

The solution is based on a fully automated mechanical system comprising a 2-axis manipulator fitted with a retractable-support gripper for precise placement of product layers into the cases. The system manages batch preparation, layer turning and coordinated loading according to the selected formats.

The installation also includes:

• A blank magazine with vacuum destacker,
• A folding chain conveyor,
• A lid magazine with its own manipulator,
• A complete glue-closing system,
• And an outfeed conveyor system with integrated labelling (not supplied by JYGA).

The solution handles several case types: wrap-around cases, trays with lids and close-fitting shelf-ready cases, with product formats ranging from 125 g to 1 kg and a throughput of 5 to 10 cases/minute depending on the format.

The operator interface provides smooth, intuitive and centralised navigation.

Industrial equipment included in the JYGA installation

The installation deployed for this food-industry application includes a range of integrated equipment providing complete automation of the case-packing cycle:

Main equipment:

• Product infeed conveyors
  • Product take-off at the packaging-machine outfeed
  • Perpendicular lug transfers for row formation
  • Accumulation against a stop and transfer to the loading unit
• Layer preparation system
  • 2-axis transfer of rows of butter portions
  • Layer turner
  • Automatic transfer into the gripper
• 2-axis manipulator with retractable-support gripper
  • Precise placement of layers into the cases
  • Repeatability and reliability
  • Fully synchronised with line throughput
• Blank magazine and vacuum destacker
  • Safe manual loading
  • 1,000 mm capacity with safety reserve
  • Management of several blank formats
• Gluing and closing system
  • Glue generator with automatic feed tank
  • Gluing of side, bottom and longitudinal flaps
  • Progressive pressing and folding over 6 stations