Precise Nut Handling
The client approached us with a unique challenge of packing bagged almonds into display bliss trays and at the same time RSC cases and utilizing automation to fit more bags into each tray than would be possible manually. It was clear from the onset that a single solution would be a challenge because the package formats were significantly different. On the display case side of things their requirement was to pack the bags upright with the labels facing out on the perimeter of the case to 3 of the open sides. This means that the orientation of the product varied depending on its position in the pattern.
The major challenge and our solutions
As we do with all the applications that come through our doors, we first develop a concept solution and prototype for feasibility. It was clear the products would need to be individually loaded to meet the orientation requirements, but there was a catch. Once the bag is vertical the almonds tend to flow downward increasing the footprint of the bag. When that occurs, there isn’t enough space in the case for all the products. Challenge accepted.
So, as you can see the product is entering the system at 60 bags per minute from two vertical baggers laying flat short side leading. An integrated Fanuc iRVision solutions is implemented to track the bags on the conveyor and manipulate without stopping the flow of products, they are picked and staged for a secondary handling solution. Picking the bags with a fork style actuated tool is performed to contain the bag but also to form it and achieve the smallest horizontal footprint inside the case. The cases arrive pre-formed from upstream and were staged at a 45-degree angle for loading, this approach shifts the center of gravity and prevents the almonds from settling to the bottom. Maintaining full control of the bags during the loading allows for orientation in any direction. The vision guided robots can be repositioned via a changeover to the south side of the cell and in turn load directly into RSC bottom sealed cases in a horizontal pack pattern.
Enhancing throughput and efficiency
Downstream the two different package formats converge onto a single palletizing solution. The palletizer with a Fanuc R1000 robot automated pallet delivery and transport system as well as two slip sheet magazines. The unit as shown is fully designed and built in-house including the pallet magazine and all case and pallet conveyors. The pallet magazine has a 10-pallet capacity or up to 15. The pallet calls for two types of sheets, a layer pad on the bottom of the pallet and a slip/tier sheet between layers. As you can see the two are uniquely positioned next to the pallet to allow for a more controlled placement solution to pick and slide the sheet across the pallet. The fork style end of arm tooling maintains control of the loaded cases and provides support to the weak points to eliminate damage due to inertia experienced through the loading process. This tool is replaced with a simplified vacuum head for handling RSC cases.
Improve the quality and larger count per tray
The equipment provided to the customer was an efficient solution for their packaging process that is ergonomically taxing on an operator. The solution also guarantees orientation of the product within the display tray without opportunities for mishandling, while improving the quality, larger count per tray and efficiency of the package. On the palletizing end the benefit is clear, lifting 40-pound cases to shoulder height is not an option.
