Furthermore, in the secondary packaging process, the new solution offers several benefits compared to the American box, which was previously used by Galbusera. It is more flexible, because a cardboard die-cut can be used to form different tray models, while the American box has standardized dimensions; and it helps to save materials used for the secondary packaging, because additional background and cardboard internal dividers are not needed.
Galbusera decided then to transform its secondary packaging concept radically. The most challenging step of the project concerned the ability of the line to realize the right batches required by Galbusera sales office and to meet the palletizing requirements: “We had to respect the quantity per sale unit and per pallet,” Scornaienchi explains. The manipulation of the finished product was another peculiarity that Livetech and Galbusera had to cater for: “We had to comply with severe constraints in moving the product along the secondary packaging and transporting steps,” Ronconi points out. “Products can’t be allowed to deteriorate in their package, in terms of shape and appearance. Tre Marie panettoni and colombe are appreciated for their high quality, and customers who choose them expect the same quality even in the packaging.”
Robots have to load the tray not only with carton-packed products, but also flow-packed products, which are conceived to be sold in outlets. “In this second case, products in bags have to be picked and moved more delicately, because they are less protected than they are in a carton box, and we initially had some perplexities: could a robot deliver the same care as an operator’s hand?” Scornaienchi continues. “Thanks to special gripping tools and advanced control configuration, the robots are able to offer delicate handling, preserving the product in both cases.”