Selecting the Best Robotic Tooling Option

Today’s manufacturers have started looking downstream more and more for automation opportunities. And when they do, more are choosing robotic systems. According to a 2009 PMMI study on packaging machinery, shipments of robotic palletizers rose by more than 3% in 2008, one of the few categories to show growth during this recessionary period. And shipments of palletizing machinery topped $500 million in 2008.

Designing a robotic palletizing cell has become more complicated as companies continue to invest in sustainable packaging. To reduce dunnage, standard corrugated cardboard cartons are being replaced with thinner-walled pressboard, shrink-wrapped bundles of product on corrugated pads and even loose product in trays. Add increased demand from club stores and marketing changes to the mix, and manufacturers need to account for a much wider range of packaging sizes, shapes and materials.

Choosing the correct end-of-arm tooling helps ensure that a new robotic palletizing or depalletizing system can effectively handle a company’s full range of packaging types. End-of-arm tooling is a highly project-specific component that represents a large percentage of the overall cost of the system. The following five questions will help you design a system that maximizes performance, speed, uptime and return on investment.

1. What kinds of product are you handling?

The first step in choosing robotic tooling is analyzing the full range of products and packaging types running on your line. Take some time to determine how each item should be handled. For example, can the packaging support its own weight during transfer? Or will it need to be supported from underneath?

Here are some important factors to consider:

• Size, shape and weight;
• Stability and construction;
• Sealing, wrapping and/or taping;
• Secondary packaging.

2. What rates do you require on your packaging line?

The throughput capabilities of your robotic system can vary greatly depending on which tool you use and the product you are palletizing. A good starting point is to determine an acceptable range of line speeds (cases per minute), which can help you better evaluate your tooling options.

3. How important are the aesthetics of your packaging?

Certain tooling types enable more pallet configurations than others. This flexibility may be needed to orient graphics for full-pallet displays and meet the demands of club stores. Some tools can cause dimpling in shrink wrap or marking on packaging, which may be unacceptable for items ending up on display.

4. Will the robot be handling slip/tier sheets or pallets?

Don’t forget to take into account tooling for robots that handle tier sheets or pallets. Also keep in mind that peripheral tooling may be required, and that handling tier sheets or pallets will reduce line palletizing rates. Reduction in secondary packaging around the product may necessitate sheets between layers to keep the palletized load stable.