[Case study] A compact top-load case packer for gnocchi pouches

Replacing an obsolete machine while maintaining the existing layout: a challenge met by MG Tech with a top-load case packer designed for packing gnocchi pouches into dihedral cases.

 

Context: Modernizing an existing installation without altering the production line

To address the need for equipment renewal, our client sought to replace an obsolete case packer with a more modern solution, while preserving the layout of their existing production line.

Two major constraints had to be considered: a small footprint to allow the new machine to fit in the space previously occupied by the old one, and highly restricted access for transporting the equipment to its final installation site.

The new system also had to automate the packing of pillow-style gnocchi pouches into dihedral cases, while meeting the required production throughput (60 pouches/min).

Project Objectives

• Replace the existing case packer with high-performance equipment tailored to production needs.
• Maintain the production line layout by using a compact machine.
• Facilitate the transport of the equipment to its final location.
• Ensure seamless integration with existing product and case flows.

 

MG Tech Solution: A compact, robotic top-load case packer

MG Tech proposed a custom-engineered top-load case packer designed to automate the packing of gnocchi pouches into dihedral cases, while accommodating the site’s specific space and integration constraints.

The machine manages both product and case flows simultaneously. Pouches are transported from the bagging area, while pre-formed dihedral cases are simultaneously conveyed to the case-packing zone.

A "dummy case" batching system groups the pouches together before they are transferred. These batches are then pushed into cases that have been tilted 90°, with combs holding the pouches in place to guide them during insertion. Once filled, the cases are returned to an upright position and rotated 90° toward the discharge conveyor.

This architecture minimizes the machine’s footprint while ensuring a smooth, automated case-packing process.

 

Technical Specifications

• Products: pillow pouches – 2 formats
• Product throughput: 60 pouches/minute
• Cases: dihedral cases – 1 format
• Case-packing rate: 7.5 cases/minute

 

Solution Highlights

Optimized footprint

The pouch-batching system reduces the overall footprint of the installation. The machine’s compact design addresses space constraints and facilitates integration, allowing it to replace existing equipment.

 

Design focused on ease of maintenance

Full-height doors provide easy access to the machine’s interior. The absence of frame bars at the base further improves accessibility to work and service areas.

 

Visual inspection of incoming products

A vision system monitors products as they enter the machine. It identifies their positioning and performs basic quality checks. Images can be viewed directly via the Human-Machine Interface (HMI), simplifying product tracking and the analysis of any potential anomalies.

 

Intuitive operation and simplified diagnostics

The machine is equipped with two HMI screens: a 15-inch primary screen and a 7-inch secondary screen. Additionally, a three-color light and sound signaling system allows for the rapid identification of areas where a fault has occurred, facilitating the diagnosis of any stoppages.

 

Safety integrated into production flows

Safety tunnels are provided at the product and case entry and exit points. As part of the machine’s overall safety system, these tunnels reconcile the movement of production flows with the protection of operators.

 

Remote support capabilities

The machine can be connected remotely to facilitate support and diagnostic operations, subject to the connection protocols established at the site.

 

 

The result: a solution adapted to real-world operational constraints

With this top-load case packer, MG Tech addresses a dual challenge: modernizing obsolete equipment and integrating a new automated solution into a space-constrained environment.

Featuring a compact batching system, a design that ensures easy access to the machine, and integrated vision and supervision tools, this solution combines space optimization with ease of operation and support for maintenance tasks.

A solution designed to meet the requirements of an existing production line, while remaining mindful of the practical constraints of installation and daily use.

MG Tech, your partner for packaging solutions.