Client project – Technical solution
Unloading Vacuum-Sealed Sachets from Trays
Product
Vacuum-sealed sachets
Packaging
Company
This project was completed for a European leader in organic and dietary foods. JYGA was contacted to replace the existing tray-unloading, cartoner-loading and case-packing section in order to improve production-line performance.
Project & solution
For the tray-unloading function, JYGA installed an automatic tray unloader. The installation includes:
- A conveyor line for stacks of trays
- A 6-axis robot
- A conveyor mounted on a rotating axis
- A mesh conveyor
- A drying unit with blower
- A row turner
- A chute system for separating sachets
- A 6-axis stack-inspection robot
- Perimeter safety guarding
- An adjacent electrical cabinet
- A robot control cabinet
Related machine
Automatic Tray Loader & Unloader
The products arrive in stacks of 19 full trays. An operator places these stacks using a handling truck.
A 6-axis robot fitted with a clamp gripper picks a full tray at the destacking station and presents it beneath a conveyor. This conveyor is mounted on a rotating axis, and the robot and axis perform a 180° rotation. The product layer is therefore placed on the conveyor with the facing side down. The robot then places the empty tray at the destacking station.
A 6-axis robot fitted with a mechanical probe checks the stack height, detects incorrectly stacked trays and verifies each tray’s position on the stack. This function ensures reliable tray pickup even if the stack is tilted or two trays are incorrectly stacked.
The product layer is discharged onto a conveyor and carried through a drying system. A blower removes water from the top and bottom of each product.
At the dryer outfeed, the products are turned over and then separated using a chute system. A belt conveyor then carries them under a vision system and to the first robot. This robot is fitted with a suction-cup gripper and prepares layers on a second belt that presents them to a loading robot.
The sachets can also be conveyed to a plastic-bin case-packing module for quarantine. Operators subsequently empty these bins so the products can be automatically sent to the cartoner.
Benefits of the JYGA solution
- Automated tray unloading: robotic destacking and emptying with no manual effort.
- High throughput: up to 100 vacuum-packed sachets per minute.
- Integrated drying: top-and-bottom air blowing removes residual water.
- Product separation: chutes and conveyors separate the sachets individually.
- Stack inspection: probe-equipped robot ensures safe, reliable tray pickup.
- Flexible flow: products can be directed either to bin packing or to the existing cartoner.
Specifications and results
| Machine | |
|---|---|
| Footprint (L x W) | Throughput |
| 13 000 x 3 500 x 2 500 mm | 100 products/min |
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