The case for robotics in the food industry

There comes a point in the production process when practically all products are picked, packed and palletized. That’s why ABB is committed to providing the best possible robots for the packaging process – always with an eye to creating an efficient and flexible production flow as well as better product quality.

Why robot-based automation?

Robot-based automation ensures the kind of flexibility you need to meet ever shorter product life cycles, new packaging designs, product variants and batch manufacturing. Compared to dedicated hard automation, robot lines are shorter and allow far better utilization of floor space. Robot-based automation is an excellent alternative to manual operation. In addition to increased up-time and total throughput, fewer accidents, better product quality and increasingly demanding workplace legislation are compelling reasons to make the shift to robotics.

The deployment of robots in the food industry is an area where technology is quickening the pace and making human hands redundant. Also, unlike humans, robots do not suffer from repetitive strain, fatigue, boredom or any of the related illnesses or conditions these provoke. Establishing the need for robots in the food industry, however, requires consideration. First, the investment needs to be cost justified, and then the system must be modeled to make the most of the capabilities of robots.

Indeed, robots often replace human workers, which is why their acceptance is often a subject of negotiation. However, robots do present a strong case of their own and this is why we are seeing more and more getting to work in food industry.

Incidences of strain industries and lost time in the food industry are a motivator for many companies to seriously consider the role of the robot. As the USA, UK, and elsewhere in Europe become more litigious, the costs against claims against businesses from workers suffering workplace related injuries will rise.

Food safety

At ABB we build our robots to meet the most demanding work conditions as well as the highest hygiene standards. In addition, all of our robots are IP 67 certified, ensuring tightly sealed joints and connectors. The IRB 340, which is most likely to handle open food, is available in stainless steel. Naturally, the hardware can be cleaned in accordance with food industry stipulations.

Picking

This is an area in which ABB services a multitude of products, applications and packaging line set-ups. Frozen food, bakery and confectionary, ice cream, meat and fish, cheese, pet food, medical products, shampoo and perfume bottles are a few examples. Capable of handling a staggering 150 picking cycles per minute, the IRB 340 FlexPicker is our star performer in this area. For full 6-axis flexibility, less demanding cycle times and payloads of up to 5 kg, we recommend the IRB 140.

Packing

In the packing stage of the packaging process, robot automation offers easy integration, increased flexibility and high reliability. Top loading of boxes, unloading and mixing, and feeding of products to end loaders or film wrappers is easily handled by ABB’s compact new 4-axis IRB 260. A robot, designed and optimized for packing applications with a payload of up to 30 kg.
With a comprehensive range of robots, controller equipment, vision technology and software, ABB can help you optimize all kinds of packing applications, including race track packing and tracking of moving conveyors.

Palletizing

Placing boxes, trays, bags, bottles or other items on a pallet seems easy enough. But, when you’re dealing with the rigorous demands of multiple feeder lines, quick box-pattern changes and high up-time, nothing compares to robot-based automation. IRB 660 has the versatility, reach and handling capacity needed for most palletizing applications. And for even greater payload requirements, we recommend our standard 6-axis robots, the largest built to handle as much as 650 kg.

Partner network

With ABB comes access to the best players on the market. To ensure you receive optimum service and complete satisfaction in every aspect of your robot automation programme, ABB has established a global network of approved partner companies, including system integrators machine builders and consultants. They not only have long experience of integrating ABB products into production processes but also share our values and focus on your satisfaction above all else.
As our partners, they benefit from our training and access to our knowledge and information resources, making them as well-equipped to work with ABB products and systems as we are ourselves.
So when you deal with any one of our global partners, you can expect the same high standards as when you deal with ABB.

Easy-to-integrate, easy-to-use

ABB spares no effort in creating smart PC-software solutions for you. Easy-to-use software packages, for picking, packing and palletizing the IRC5 controller and graphical FlexPendant, work in unison to enhance robot programming and operation.

PickMaster

ABB’s dedicated PickMaster soft-ware makes programming and re-programming easy.
PickMaster is ABB’s standard soft-ware solution for integrating cam-eras, vision system and conveyors with picking and packing robots. It is specifically designed for easy integration of ABB’s robots to a wide range of random material flow hand-ling applications. In fact, it’s ideal for running combined high-speed picking and case packing systems.
PickMaster integrates up to 8 cam-eras and 8 robots and multiple conveyors for each robot using the industry benchmark – the Cognex vision system. In addition, it houses quality control/inspection capabilities, as well as functions for advanced mixing and sorting.
Ultimately, PickMaster elevates robot performance to new levels of efficiency.

In conclusion

In summary, once the case for the robot has been analyzed, it is important to address the economics in the process. Measured against human costs, this may be justified, but once line efficiency has been considered, payback may not just come from reduced costs, but also from increased productivity, efficiency and quality. Perhaps the major advantage is the high level of flexibility offered by robotics today. Slight alterations can be made to the robot, so that it is able to cater for a new product in a matter of minutes, without the use of tools.

As the food industry continues to respond to greater product variations and ever more stringent regulations, more manufacturers will be turning to robotics for save, flexible and speedy automation solutions.