[Case study] Automation of a complete end-of-line packaging process for the seafood sector

Context

Today, consumption patterns are evolving, and demand is growing for ready-made meals, particularly pre-packaged fish fillets, while fishmongers are becoming increasingly rare in supermarkets.

Our client, a well-established French manufacturer in the seafood, processed vegetable, and, more recently, vegetarian food markets, has chosen to expand one of its facilities to increase production and meet consumer demand.

As part of this investment, they partnered with MG Tech to develop two complete automated lines that integrate case forming, automated product packing, and robotic palletizing.

 

Technical features

Products:

• 2 sizes of thermoformed trays with different heights
• Nominal production rate: 75 trays/min (up to 95 trays/min at higher speeds)

Cases:

• Cases with corner edges and dowels
• 6 sizes of cases with different heights
• Production rate: 16 cases/min

Pallets:

• Dimensions: 1200x800 mm
• 1 size in terms of dimensions / 2 sizes in terms of reference
• Production rate: 36 pallets/hour

 

Provided solution

To meet its line automation needs, MG Tech proposed two complete packaging lines, installed facing each other, including:

Case forming (x2 Ecobox case erectors)

The two high-capacity Ecobox case erectors were designed to handle five standard corner edge case sizes (the length and width are the same; only the height differs between sizes). At the output, they include a case squareness control station and an infeed conveyor for connection to the vertical lowering conveyor.

Due to space constraints, the two case erectors are installed on a mezzanine, above the case packing and palletizing line.

Product case packing (x2 top-load case packers):

Product conveying system:
A product transfer conveyor moves the trays to the pacing conveyor, which ensures spacing between products on the tracking conveyor. The tracking conveyor then transfers the products for robot picking, indicating the exact position of the tray on the conveyor and checking the product height. If the products do not conform, they are removed by a gravity conveyor into a waste bin.

 

Case conveyor system:
The case conveyor transfers the case from the vertical lowering conveyor to the case packer and connects to the case erector on the upper level. The cases are then fed into a cleated chain that advances the cartons through the various steps of the machine.

 

Case Packing:
The products are picked up and placed into cases by two 5-axis Delta robots with suction cups. Case packing takes place over four loading steps.

 

Full case controlling:
The full cases are weighed immediately after case packing to verify the correct number of trays in each case.

 

Case labeling:
Four labeling machines were integrated by MG Tech to apply labels to the short side of the case. This ensures uninterrupted production with a backup labeling machine should the first one stop.

 

Ejection of non-conforming case:
Non-conforming cases (incorrect weight, labeling defects, etc.) are removed via a gravity-fed ramp.

 

Elevator:
The full cases are then transported by elevator to the robotic palletizing area.

Palletizing of full cases (x 2 palletizers):

The two robotic palletizers are secured by a wire mesh enclosure with light curtains and access controlled by individual badges. They are equipped with Fanuc 6-axis robots with a capacity of 225 kg.

The cases are conveyed to a row-preparation conveyor, allowing the forklift to pick up a batch of four cases.

Management and transfer of empty and full pallets (1 shuttle system + 1 pallet destacker)

Empty pallets are distributed thanks to two destackers.

A double-level rail shuttle, serving both palletizers, allows for both the supply of empty pallets via the lower level and the retrieval of full pallets via the upper level.

Five independent motorized conveyors have been integrated, allowing for the storage of one pallet inside the shuttle's enclosure and the storage of four additional pallets outside the shuttle's enclosure.

 

Why choose MG Tech?

For almost 20 years, MG Tech has been supplying packaging equipment to our client. They have once again placed their trust in our company. The relationship between our two companies is excellent.

"We have been working with MG Tech since 2007 and are very satisfied with the collaboration. We already have Ecobox case erectors and top-load case packers in our production site. We chose MG Tech again because we want to replicate what has been implemented and what works."

 

The advantages of the solution:

The ability to provide all packaging functions is a real advantage. This allows the client to have only one point of contact for both lines.

The various machines are perfectly modular and will allow the installation to be expanded to include a third line as needed.

The proposed technical solution for the palletizing island is a real plus in the installation: it allows for the management of both empty and full pallets thanks to its double-level shuttle system.