Automating high-speed case packing to boost ready meal throughput
Project snapshot
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Challenge
Multi-variant case packing integration
The customer required an automated solution to pack ready meals into cases ahead of shipping. The system needed to accommodate multiple product types of varying sizes and quantities per case while integrating with an existing sleeving line.
Innovation
Integrated robotic case packing system
We developed a fully automated end-of-line solution that moves meals from the sleeving line to palletized cases:
- Transferred ready meals using a robotic pick-and-place system with integrated vision for auto-rejecting mislabeled items
- Designed modules to erect cardboard boxes, seal the undersides, and transfer to the top-loading robot
- Implemented a four-at-a-time loading system using suction cups for fast, precise placement
- Integrated case closing and sealing modules using hot melt glue
- Developed palletizing with six-axis robots, automatic de-stacking, and full pallet ejection
Result
Increased throughput and flexibility
The system achieves up to 80 ready meals per minute, handles multiple product variants, and has enabled the installation of a second line to further boost production efficiency.
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