Efficient palletising in the food industry: a compact PalCobot solution for F.F.P. NV

With our PalCobot XL, equipped with a FANUC CRX-30iA Food Grade cobot, boxes at the end of the packaging line are stacked onto pallets fully automatically and safely. The result? A compact installation with high reliability, minimal operator intervention and a small footprint.

Case

F.F.P. NV was looking for a solution to palletise boxes automatically at the end of the packaging line. The key requirements were:

• A set-up that is as compact as possible;
• Box dimensions: 285 × 385 × 250 mm;
• Weight: 10 kg;
• Capacity: 6 boxes per minute;
• Maximum stacking height: 2,050 mm;
• Euro pallets of 800 × 1,200 mm;
• Automatic placement of slip sheets;

Why choose a PalCobot?

Thanks to its limited footprint, a PalCobot can easily be integrated into existing production areas without major modifications. Moreover, the intuitive software lets operators create new stacking patterns themselves without any programming knowledge.

Depending on the application, the PalCobot can be equipped with different grippers, conveyor systems, lift kits or extra pallet positions. This way, the installation easily grows with future production needs.

A food-grade cobot for maximum reliability

For this project, we chose a PalCobot with a FANUC CRX-30iA Food Grade cobot.

This collaborative robot was specially developed for applications in the food industry and features, among other things:

• NSF-H1 food-grade lubricants
• White epoxy coating
• Corrosion- and chemical-resistant finish
• IP65 protection against dust and splashing water
• Payload of up to 40 kg
• Reach of 1,756 mm

This makes the cobot perfectly suited for production environments where hygiene and reliability are paramount.

A vacuum gripper tailored to the application

The boxes are picked up with a Schmalz FQE-V vacuum gripper.

This gripper combines a low dead weight with a large contact surface of 400 × 280 mm, so every box is picked up safely and stably. Thanks to its rounded design, the gripper also meets the requirements of ISO/TS 15066, the international safety standard for collaborative robots.

An additional advantage of the chosen gripper is that the vacuum is generated inside the gripper. This means no external vacuum pumps, hoses (the vacuum hose is routed inside the cobot arm) or additional components are needed, which makes the installation more compact and easier to maintain.

Smart buffering prevents production downtime

An important part of the project is the new powered stainless steel roller conveyor.

After all, the packaging lines must be able to keep producing during a pallet change. That is why a buffer was provided that can absorb about one minute of production.

The roller conveyor consists of:

• a buffer zone;
• an acceleration zone;
• a pneumatic stopper between the two zones;
• fixed side guides for controlled product flow;
• a sensor for box detection.

By choosing a powered roller conveyor instead of a gravity system, boxes are prevented from pressing against each other, so the cobot can pick up every box without any problems.

Safety without compromising on productivity

Although a cobot is designed to work safely alongside people, safety remains an essential part of every automation solution.

For this installation, we chose safety fencing combined with a safety floor scanner at the front of the cobot installation. This allows operators to change pallets safely while the cobot continues working in a controlled way at a lower speed. A sliding door is provided in the side of the fencing so the operator can easily replenish slip sheets in the dedicated magazine.

Intuitive software without licence fees

The software provided is our standard PalCobot software, developed in-house. Via a modern HTML interface, operators can create new stacking patterns and monitor and adjust the stacking process.

Moreover, error messages and log files can be consulted at any time, in 4 languages: Dutch, English, German and French.

Because the software is web-based, the installation can also be monitored remotely if desired. And all this without recurring licence fees!

From design to delivery

As with all our projects, we guide the customer throughout the entire process. After engineering, the installation is assembled in our workshop. We then carry out an extensive Factory Acceptance Test (FAT) together with the customer, during which several pallets are built up completely.

After installation on site comes the Site Acceptance Test (SAT), after which operators receive practical training and all necessary documentation is handed over, including the manual, risk analysis and CE documentation.

Compact automation with maximum flexibility

By combining a food-grade cobot, integrated safety provisions and user-friendly software, F.F.P. NV has a future-proof palletising solution that is reliable, safe and exceptionally compact.

Are you also looking for a compact palletising solution for your production environment? Feel free to contact our specialists. We would be happy to see how a PalCobot can make your production more efficient too.