Streamlining high-speed confectionery repackaging with automated secondary packaging
Project snapshot
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Challenge
Replacing inefficient manual repacking
A market leader in the confectionery industry needed to replace an aging, highly inefficient, manually managed repacking line. The existing process limited throughput and introduced unnecessary complexity.
AIR was engaged to develop a simplified, automated solution capable of packing multiple products at high speed while integrating with existing downstream equipment.
Innovation
Automated buffering and high-speed robotic feeding
Following detailed consultation to define functional and technical requirements, we designed an automated secondary packaging solution focused on balancing product flow and maximizing packing efficiency. The system was engineered to manage multiple input streams while maintaining flexibility and speed.
- Custom buffer store to accommodate material changes and balance product flow
- Delta robot to pick and feed products at high speed
- Integration with an existing third-party flow-wrap system
- Custom vacuum grippers to handle products and create multiple stack formats
- HMI-driven format selection for flexible operation
Result
Balanced throughput and simplified repackaging
In operation, products arrive at the automated packaging machine from two separate production lines at 60 and 80 parts per minute. The custom buffer store equalizes flow from both lines before feeding products to the loading robots. Using custom vacuum grippers, products are picked, stacked into the required formats based on HMI selection, and fed consistently into the flow-wrap system, delivering a significantly simplified and more efficient repackaging process.
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