We have completed more than 150 automated handling, case packing, palletizing and warehousing applications, using state-of-the-art robotic and automation technologies. These systems operate seamlessly in factories within the Food, Beverage, Pharmaceuticals, Packaging Materials, and other industries, contributing to increased productivity and reduced costs.
The extension of the system we have installed at Tasty Foods contributed to the full automation of the case handling process of the factory. The system receives carton cases from two production lines on a conveyor line. The cases are then raised by a lift at 3,5m and conveyed parallel to the wall. The last part of the line is inclined, so the cases are brought back to 1m from the ground, and the conveyor line is merged to the existing line.
What Tasty Foods required was an automated handling and sorting process for carton cases to be palletized, aiming at reduced costs and increased production and warehousing flexibility. Zenon Automation SAICT designed and installed an integrated solution, which completes the process in four (4) steps: 1) Carton case labelling & handling, 2) case barcode reading, 3) carton case sorting and 4) case grouping & palletizing.
We have designed and installed an automated case packing system for Joconda pralines in two different carton cases (1 and 3 kilos). The system includes two SCARA robotic arms (Adept), a servo-controlled grouping module, product and carton case conveyor belts, and photocells for quality and quantity control of packed pralines. The system was taken out of production, when the production company, Pavlidis, discontinued this type of packaging.
Three robotic systems have been designed and installed for loading/unloading trolleys with serum containers. With the help of a FANUC M420 robotic arm, the two loading systems receive the serum containers from the corresponding production line and load them on metal trolleys with drawers, in order to convey them to the sterilization oven. The systems include a plastic chain conveyor, a lift to handle the trolley drawers and a chain conveyor for the trolleys.
The robotic unloading system unloads the sterilized serum containers from the trolleys and in-feeds them to the label applicator and the robotic case packing system. It includes a FANUC M420 robotic arm, a lift with drawer handling mechanisms, and a chain conveyor for the trolleys. It is worth mentioning that, quite often, during conveyance and sterilization of the trolleys, the serum containers are displaced on the drawer. We have therefore designed a special gripper to deal with this problem. The system can handle serum containers of 1000ml, 500ml, 250ml & 100ml, and the changeover process is simple and fast.
A robotic system for case packing serum containers in different carton cases. It includes a FANUC M421 robotic arm, a pneumatically activated serum grouping module, case formers and sealers, and a chain conveyor for carton case conveyance. The system can handle serum containers of 1000ml, 500ml, 250ml &am; 100ml, in eight different carton case types. The system is fed with serums by a robotic unloading system for the trolleys, and the packed carton cases are forwarded to a robotic palletizing system, thus automating the entire packaging procedure.
With the robotic systems we designed and installed at Delica S.A., the company has fully automated the palletizing process of their products (paper rolls, toilet paper bundles, kitchen towel bundles). The company has achieved in this way a drastic cut of the production costs, and consistency in the pallet production rates.
This integrated solution includes: two FANUC robots, a case conveyor system (lifts, inclined roller conveyors, etc.), palletizing roller conveyors, an in-feed mechanism for empty pallets, a shuttle car for removal of pallets, a stretch wrapping machine, a safety fence and an electrical control panel.
The robotic system we designed for Cosmos Lac, automated the palletizing procedure of carton cases with colour spray containers. A Fanuc robotic arm takes the carton cases and places them, according to a predetermined pattern, on a pallet rested on a palletizing roller conveyor.
During palletizing, each time two layers are completed, the robotic arm takes a carton sheet from a stack and places it on the pallet using the same gripper. When the pallet is full, the palletizing roller conveyor is activated to convey the pallet from the pallet loading station to the waiting station, to be removed by a pallet fork. When the pallet loading station is free, the robotic arm, using the same gripper, takes a new pallet from the stack and places it on the station to continue with the procedure.
The solution we implemented at Cosmos Lac covered the need for automated and faster case packing of spray containers. The system includes a carton case forming machine, a case packer and a case sealer. The completed carton cases are lead to a robotic palletizing system.
Case packing of the colour containers is carried out by a machine especially designed by Zenon. This machine is a Cartesian, servo-controlled mechanism. It initially groups the products according to a predetermined pattern, and then places them, with the help of a pneumatically activated gripper, inside the empty carton case. Particular attention has been paid to speed, safety (flammable product), and ease of changeover regarding containers and carton cases.
We have designed and installed an automated system for the conveyance of sliced bread from the slicing machine initially to two overwrapping machines, and then to a machine that inserts the bread in a plastic bag. The system includes a SCARA robotic arm by Adept, which takes the sliced bread from the slicing machine and feeds it in the overwrapping machines. Then, a pneumatically controlled ΧΖ mechanism (designed by ZENON) feeds the wrapped bread, one-by-one or in pairs, to a machine that inserts them in a plastic bag. The system is very fast (60 loafs/minute) and reliable. It is also an excellent application sample of a robotic arm serving pre-existing, semi-automatic machines in a factory. The system was taken out of production, when Chipita discontinued the production of sliced bread.
The integrated solution we designed for Astir Vitogiannis Bros SA automated the secondary and tertiary packaging procedures and includes: Carton case forming, packaging, conveyance, sorting and sealing line and robotic palletizing for cases, using packaging materials, and stretch wrapping.
With the system we designed and installed at ASPIS Dedes S.A., the company fully automated the palletizing process of the factory in Argos, thus significantly reducing production costs.
Through roller conveyors, the system receives carton cases with juice from the out-feed of two packaging machines and conveys them to the robotic system. The cases are then grouped appropriately. An especially designed gripper of the FANUC robotic arm, facilitates the correct layering of the carton cases on pallets, according to a predetermined pattern, at two loading stations located on the palletizing roller conveyors. As the system takes the empty pallets from stacks of 12, the operator is only required to insert stacks of empty pallets and remove the full pallets.