[Case study] Automation of case packing for bakery products in various formats

Context

A player in the industrial bakery sector, our client was seeking a solution capable of automating the end-of-line case packing of various product types.

The project presented several challenges: handling both bags from three vertical bagging machines and folding cartons from a cartoning machine, while ensuring high throughput rates and great production flexibility.

Another unique aspect of the project was that the shipping cases themselves did not yet exist. Their design therefore required a genuine co-development effort involving the client, the carton manufacturer, and the MG Tech teams to create a solution perfectly tailored to the products and the case-packing process.

 

Technical features

The line had to be capable of handling various product types at high speeds:

• Pillow bags and flat-bottom bags: up to 171 products per minute
• Compact cardboard cartons: up to 130 products per minute
• Wrap-around cases: up to 14 cases per minute

The challenge, therefore, was to design a high-performance, versatile system capable of fitting into a constrained production space.

 

Solution designed and provided by MG Tech

To meet the client's needs, MG Tech designed a complete line comprising conveyor systems, a converging unit, and a wrap-around case packer.

The system's unique feature is its ability to handle multiple product flows and automatically route them to a single case-packing machine.

 

Optimized pouch handling

Pouches from the three vertical bagging machines are first transported via conveyor systems to the converging zone.

A camera monitors the products upon entry to ensure correct orientation.

The three lanes of pouches are then merged into a single lane using Delta robots, which pick and place the products with speed and precision.

The merged lane is then conveyed directly to the case packer.

Direct compact cardboard carton transfer

Solid-board cartons—or product batches—follow a different path.

They are transported directly from the cartoner to the case packer in a single lane, without intermediate handling, to maintain flow continuity and product integrity.

 

Wrap-around case packing

At the heart of the line, the wrap-around case packer handles the casing of the various product types.

The case is formed progressively as the products move through the machine, following the wrap-around packing principle.

Pouches or cartons are then loaded into the case by Delta robots before the case is fully sealed.

The machine also performs the following functions:

• Forming the case around the products
• Automated loading of pouches or cartons
• Case sealing
• Inspection and identification of each case

The advantages of the solution

This solution was designed to meet the client's specific constraints while facilitating daily line operations.

 

A single machine for multiple product types

The solution allows a single case packer to handle widely varying product types:

• Pillow bags
• Flat-bottom bags
• Solid board cartons

This versatility provides the client with a flexible, optimized installation.

 

Quality control at the line entry point

A camera positioned at the infeed of the convergence system monitors bag orientation.

This check ensures products are correctly positioned before being picked up by Delta robots, contributing to the reliability of the entire process.

 

Simplified maintenance

The machine’s design also focuses on simplifying maintenance tasks.

Full-height doors provide operators with easy access to the case packer’s interior and various machine components.

 

Quick and intuitive format changeovers

Format changes are streamlined thanks to:

• Automated programs
• Handle-based systems
• Simple, intuitive reference markers

Operators can thus quickly adapt the machine for different production runs.

Layout adapted to site constraints

Finally, the case packer features an L-shaped layout, designed to fit the packaging area's spatial constraints and optimize the use of available space.

 

A complete, custom-made solution

With this installation, MG Tech has developed a comprehensive case-packing solution capable of handling multiple product flows and packaging types on a single line.

Beyond technical performance, this project highlights the value of a collaborative approach. Joint development of the cases by the client, the carton supplier, and MG Tech resulted in a solution perfectly tailored to the products, throughput rates, and production site constraints.

A custom-designed, flexible, and high-performance line, built to meet the demands of industrial baking.