Robot-assisted intelligent production and packaging will maximize profitability

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The coronavirus pandemic has accelerated a challenge that manufacturers have to weigh between the long-term spread of consumer demand and the reduction in scope (SKU) caused by rapid changes in buying habits by retailers and consumers.
This results in manufacturers having to deal with existing assets more flexibly. Therefore, these assets in the form of single or connected machines must be more flexible than ever before, which means they must be provided with the right materials and packaging at the right time. In order to reduce storage costs and waste, companies in this industry hope to produce only the products needed for transportation.
Autonomous mobile robots (AMR) and collaborative robots (cobots) as well as traditional industrial robots are being used in more and more factories to replace conveyor belts or stacking/buffer stations. The challenge is to create a flexible, continuous production process for customer-specific manufacturing, and to minimize the expensive, rigid and maintenance-intensive conveyor sequences that usually require considerable space. Companies that break new ground by using innovative technologies not only gain flexibility, but also reduce waste, pollution risks, waste and losses.
The latest Mintel report identified three major food and beverage trends that may emerge by 2030:
In this case, an important question is: How can the project be realized cost-effectively and obtain a tangible return on investment (ROI)? A key focus is smart production and packaging lines that can be easily reconfigured to meet changing market and consumer needs.
The development, construction and use of such lines require a wealth of knowledge and experience to ensure that investment can reach its full potential. Therefore, detailed planning, the advice of experienced partners and innovative solutions are the key elements to improve the performance of the production line. They provide the basis for the future-oriented flow of goods and consumables in the factory hall and adjacent storage areas.
Anyone who is serious about automating the machine loading and unloading process can benefit from five advantages:
Many companies in the food industry are planning more flexible and seamless production and packaging lines for customer-specific products. This will minimize the need for expensive and inflexible conveyor processes. Ideally, an easy-to-configure production line will consist of collaborative and flexible transportation and transfer solutions, tailored to a specific production environment. Examples include robotics, AMR, collaborative robots, and recent solutions that combine the two. Their tasks include transporting work-in-process (WIP) inventory between sites or adjacent areas, a process that is managed and controlled by a special fleet management solution. Reconfigurable systems in the food industry link assets and reduce costs by storing only what is needed on the route. The traceability of all inventory levels also reduces downtime. At the same time, it can reduce the risk of tripping and support employees.
To avoid production downtime, line-side replenishment (LSR) must be carried out in a timely manner, focusing on the loading of raw materials, the packaging of containers, and the distribution of finished products. Palletizers play a central role in adding the latter theme and improving the productivity, flexibility and traceability of the production process. Innovative robotic solutions help increase throughput in these areas. Examples include SCARA (Selective Compliance Assembly Robotic Arm) solutions for loading bottles or other containers; robots for loading cartons and cartoners; and high-speed parallel robots for orientation and alignment of raw materials and primary/secondary packaging items solution. By reading and verifying item-level and batch-level labels and integrated image processing systems, traceability in the process can be ensured.
Many changes have taken place in the handling and scheduling of goods, because retailers hope to reduce costs and personnel-related expenses in this area. Food companies face the challenge of picking, placing, and sorting incoming products at the same time. Careful product handling can ensure production line throughput, reduce waste and prevent damaged goods from entering downstream processes.
Providing retail-ready solutions and avoiding costly fines and recalls can be complicated. Automation can help protect products and increase the OEE of a machine or production line by reducing downtime. In the primary product stage, fast, accurate, repeatable and efficient processing is required. Delta robots are usually the solution. Custom software also improves flow rate and recipe processing. One controller is responsible for all functions (such as motion, vision, safety, and robotics).
By automatically positioning the goods on the conveyor belt, product-friendly conveyor belt control can be achieved. For example, Omron’s Sysmac control platform has an intelligent conveyor belt function block (FB), which can control the distance and positioning of the product, reduce product damage and increase throughput.
The automated flow of goods and optimized loading and unloading of machines will play a central role in the future food factories. Companies that want to speed up processes, reduce costs, and reduce the burden on employees can use innovative technologies and robotics to achieve this goal, thereby making a big step toward competitiveness and sustainability.
What should manufacturers in the food industry look for when automating the flow of goods? What pitfalls should be avoided? The following four tips will help you understand the importance of simplifying the machine loading and unloading process.
Flexibility, quality, workforce related issues and sustainability are just some of the key drivers that we recognize when we talk to customers.
Automation can be used to continuously monitor and report processes, giving manufacturers real-time access to information on topics such as takt time, downtime, quality performance, and availability. If deployed properly, it can be used for monitoring during the definition phase of the process, so that it can identify bottlenecks and measure and understand incremental changes.
In the context of the physical movement of goods in the production environment, it is essential to protect labor from physical harm. The same workforce understands the details of these movements and should be included in the discussion on how to improve the process. After all, this is about supporting automation of the labor force.
It is important to ensure that technology partners have a broad and diverse portfolio of automation products, including comprehensive and adaptive solutions to individual challenges. It is also meaningful to have a network of system integrators that provide professional knowledge and services tailored to the industry at all levels.
The quality of a factory, production line or machine depends on the services it receives in terms of raw materials, packaging and consumables.
Therefore, companies should not distinguish between machines and production lines-focusing on improvements, such as replenishing packaging materials on the production line or minimizing WIP to reduce waste, scrap and storage costs. Only by improving the overall process, food and beverage companies can optimize labor productivity and significantly improve the performance of production lines or machines.
As a leader in the field of industrial automation, Omron has a wide range of control components and equipment, from vision sensors and other input devices to various controllers and output devices, such as servo motors, and a series of safety devices and industrial robots. By combining these devices with software, Omron has developed a variety of unique and efficient automation solutions for global manufacturers. Based on its advanced technical reserves and comprehensive equipment range, Omron puts forward a strategic concept called “innovative automation”, which consists of three innovations or “i’s”: “integration” (control evolution), “intelligence” (intelligent development) ) ICT) and “interaction” (new coordination between humans and machines). Omron is now committed to bringing innovation to the manufacturing site by realizing this concept.
Based on the core technology of “sensing and control + thinking”, Omron is a global leader in the field of automation. Omron’s business areas cover a wide range, from industrial automation and electronic components to social infrastructure systems, healthcare and environmental solutions. Established in 1933, Omron has approximately 30,000 employees worldwide and is committed to providing products and services to approximately 120 countries and regions. In the field of industrial automation, Omron supports manufacturing innovation by providing advanced automation technology and products and extensive customer support to help create a better society. For more information, please visit the Omron website: http://www.industrial.omron.co.za
For inquiries about Omron Industrial Automation, please contact: Omron Electronics (Pty) Ltd Tel: 011 579 2600 Direct Email: info_sa@omron.com Website: www.industrial.omron.co.za
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