Very Simple: Do You Need Flexibility? Robotics (collation and packing applications) can add tremendous value to your production line particularly if your ultimate customer, that is the consumer in the shops, is expecting a package that contains a variety of flavours, scents or sizes in their most common household purchases. Robotic handling easily allows variety packs to be intelligently collated / assembled, as a single robot can pick from a number of production lanes and pack slightly differing products into a single carton, case or pallet. Pack patterns can also be altered - for a different region for example - with simple programming adjustments. Robotic systems are inherently flexible and lend themselves to simple reconfiguration even in the face of dynamic production realities.
One of the most novel advantages of robotics is combined packing. Langen has developed the LRC-700 which has the flexibility to simultaneously tray pack, case pack and/or palletise. In the autumn of 2006 Langen installed a system that tray and case packs, and palletises, medical pouches; another system does the same for trays of batteries (see Panasonic example below).
Robotic systems are ideal for customers who are selling short-lifecycle products. Changing over to a new product or package can be costly; however, a robot can be re-programmed and re-tooled at a relatively low-cost and within a short time frame – you do not need to re-purchase a major component of your capital asset stock. Thus, the reward for using robotic collation and packing is the ability to take the lead in consumer markets by responding faster to demand changes, which can impact market share.
When specifying robotics, it is also critical to consider the future. Perhaps the greatest and most overlooked advantage of robotic systems is that they are highly redeployable capital assets. For example, a robotic system purchased today is easily modified to handle future product codes that may differ in size, shape or weight. Or even new applications. A case packing robot handling cartons today offers the owner the flexibility to pack bottles tomorrow. In this way, owners of robotic systems can earn a higher payback on their investments as sales are boosted as the asset’s life-time is extended.
Case Study Examples
SipTop (Toronto, Canada)
Challenge
SipTop’s drink filled pouches are becoming increasingly popular in North America and abroad and a much greater production speed was required to meet market demand. Brute speed was of course not the only requirement, efficiency and cost reduction were also vital to ensure the economics made sense both today and in the future. A new robotic solution – and a new way of looking at robotics - was offered by Langen and ultimately replaced SipTop’s existing robotic packaging line. The Langen solution:
- Improved efficiency while ensuring product integrity
- Sped up the packaging operation to keep up with the growing production operation
- Reduced labour costs
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