Loading
Rockwell Automation Home
  • Industries
    • Industries Chevron RightChevron Right
      • Automotive & Tire
      • Cement
      • Chemical
      • Entertainment
      • Fibers & Textiles
      • Food & Beverage
      • Household & Personal Care
      • Infrastructure
      • Life Sciences
      • Marine
      • Metals
      • Mining
      • Oil & Gas
      • Power Generation
      • Print & Publishing
      • Pulp & Paper
      • Semiconductor
      • Water Wastewater
      • View All
    Industries
    Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
  • Capabilities
    • Capabilities Chevron RightChevron Right
      • The Connected Enterprise®
      • Consulting & Integration Services
      • Cybersecurity
      • Digital Transformation
      • Industrial Analytics
      • Industrial Automation & Control
      • Industrial Maintenance & Support
      • Industrial Networks
      • Lifecycle Services
      • Machine & Equipment Builders
      • MES Solutions
      • Process Solutions
      • Safety Solutions
      • View All
    Capabilities
    Blogs DistributorDistributor How to Buy EventEvent Events
  • Products
    • Hardware Chevron RightChevron Right
    • Software Chevron RightChevron Right
      • Circuit & Load Protection
      • Condition Monitoring
      • Connection Devices
      • Distributed Control Systems
      • Drives & Motors
      • Energy Monitoring
      • Human Machine Interface
      • Independent Cart Technology
      • Industrial Computers & Monitors
      • Input/Output Modules
      • Industrial Control Products
      • Lighting Control
      • Motion Control
      • Motor Control
      • Networks Security & Infrastructure
      • Packaged Solutions
      • Power Supplies
      • Programmable Controllers
      • Push Buttons & Signaling Devices
      • Relays & Timers
      • Safety Instrumented Systems
      • Safety Products
      • Sensors & Switches
      • Signal Interface
      • View All Hardware Products
    • DesignSuite
      • Dynamic Digital Twin Software
      • Studio 5000 Design Software
    • OperationSuite
      • FactoryTalk Edge Gateway
      • FactoryTalk Batch
      • FactoryTalk Historian
      • FactoryTalk View - HMI Software
      • FactoryTalk Metrics
    • MaintenanceSuite
      • FactoryTalk Analytics for Devices
      • FactoryTalk AssetCentre
      • FactoryTalk Emonitor
      • FactoryTalk Network Manager
      • FactoryTalk TeamONE
      • Fiix CMMS
    • InnovationSuite
      • Augmented Reality
      • FactoryTalk Analytics
      • MES
      • ThingWorx IIoT Platform
    Products
    Find Products by Our Brands: Allen-Bradley FactoryTalk
  • Support
    • Product Support Chevron RightChevron Right
    • Documentation Chevron RightChevron Right
    • Knowledgebase Chevron RightChevron Right
    • Training Chevron RightChevron Right
    • Downloads
      • 2D & 3D Drawings
      • Activations
      • Add-on Profiles
      • Application Code Libraries
      • Compatibility & Downloads
      • Drivers & Firmware
      • Electronic Datasheets
      • EPLAN Macros
      • Sample Code Library
      • Software Patches
      • View All
    • Selection & Configuration
      • Control Systems Configuration Tools
      • Procurement Specifications
      • ProposalWorks Proposal Builder
      • Global Short-circuit Current Ratings Tool
      • Integrated Architecture Builder
      • View All
    • Compatibility & Migration
      • Migration & Modernization
      • Lifecycle Status
      • Product Replacement Lookup
      • View All
      • Technical Documentation Center
      • Technical Specifications
      • Product Certifications
      • Product Drawings
      • Release Notes
      • Literature Library
    • Support Center
      • Support Options
      • Search for Answers
      • Chat Online
      • Call Us
      • View All
    • Online Forum
      • My Inbox
      • My Favorites
      • My Subscriptions
      • View All
    • My TechConnect
      • Chat History
      • Service Ticket History
      • Manage Your Favorite Answers
      • Field Service Request
      • View All
      • E-Learning Courses
      • Instructor-led Courses
      • Training Workstations
      • View All
    Support
    Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
  • Company
    • Events Chevron RightChevron Right
    • News Chevron RightChevron Right
    • Careers Chevron RightChevron Right
    • PartnerNetwork Chevron RightChevron Right
    • About Us Chevron RightChevron Right
    • Featured Events
      • Automation Fair
      • Process Solutions User Group
      • Rockwell Automation On The Move
      • Rockwell Automation TechEd
      • ROKLive
      • PACK EXPO CONNECTS
      • View All
    • Webinars
      • Live
      • On-Demand
      • View All
      • Blogs
      • Case Studies
      • Automation Today
      • Podcasts
      • Press Releases
      • View All
      • View Jobs
      • Teams & People
      • Hackathon
      • Employee Video Spotlight
      • Authorized Distributors
      • Encompass Product Partners
      • Licensed Developers
      • OEM Partners
      • Strategic Alliance Partners
      • System Integrator Partners
      • PartnerNetwork Portal
      • View All
      • Our Brands
      • Our Community
      • Our History
      • Integrity & Sustainability
      • Investor Relations
      • View All
    Company
    ProductivityProductivity Investor Relations
  • Sales
  • Sales
  • View All Industries
  • View All
  • View All
  • View All
  • View All
  • Automotive & Tire
  • Cement
  • Chemical
  • Entertainment
  • Fibers & Textiles
  • Food & Beverage
  • Household & Personal Care
  • Infrastructure
  • Life Sciences
  • Marine
  • Metals
  • Mining
  • Oil & Gas
  • Power Generation
  • Print & Publishing
  • Pulp & Paper
  • Semiconductor
  • Water Wastewater
  • View All
  • The Connected Enterprise®
  • Consulting & Integration Services
  • Cybersecurity
  • Digital Transformation
  • Industrial Analytics
  • Industrial Automation & Control
  • Industrial Maintenance & Support
  • Industrial Networks
  • Lifecycle Services
  • Machine & Equipment Builders
  • MES Solutions
  • Process Solutions
  • Safety Solutions
  • View All
  • Circuit & Load Protection
  • Condition Monitoring
  • Connection Devices
  • Distributed Control Systems
  • Drives & Motors
  • Energy Monitoring
  • Human Machine Interface
  • Industrial Computers & Monitors
  • Input/Output Modules
  • Industrial Control Products
  • Lighting Control
  • Motion Control
  • Motor Control
  • Networks Security & Infrastructure
  • Packaged Solutions
  • Power Supplies
  • Programmable Controllers
  • Push Buttons & Signaling Devices
  • Relays & Timers
  • Safety Instrumented Systems
  • Safety Products
  • Sensors & Switches
  • Signal Interface
  • View All Hardware Products
  • View All
  • View All
  • Technical Documentation Center
  • Technical Specifications
  • Product Certifications
  • Product Drawings
  • Release Notes
  • Literature Library
  • View All
  • Instructor-led Courses
  • Training Workstations
  • View All
  • View All
  • Blogs
  • Case Studies
  • Automation Today
  • Podcasts
  • Press Releases
  • View All
  • View Jobs
  • View All
  • Authorized Distributors
  • Encompass Product Partners
  • Licensed Developers
  • OEM Partners
  • System Integrator Partners
  • PartnerNetwork Portal
  • View All
  • Our Brands
  • Our History
  • Investor Relations
  • View All
  • iTRAK Intelligent Track Systems
  • MagneMover Lite Intelligent Conveyor System
  • QuickStick Intelligent Conveyor System
  • View All
  • Dynamic Digital Twin Software
  • Studio 5000 Design Software
  • FactoryTalk Edge Gateway
  • FactoryTalk Batch
  • FactoryTalk Historian
  • FactoryTalk View - HMI Software
  • FactoryTalk Metrics
  • FactoryTalk Analytics for Devices
  • FactoryTalk AssetCentre
  • FactoryTalk Emonitor
  • FactoryTalk Network Manager
  • FactoryTalk TeamONE
  • Fiix CMMS
  • Augmented Reality
  • FactoryTalk Analytics
  • MES
  • ThingWorx IIoT Platform
  • 2D & 3D Drawings
  • Activations
  • Add-on Profiles
  • Application Code Libraries
  • Compatibility & Downloads
  • Drivers & Firmware
  • Electronic Datasheets
  • EPLAN Macros
  • Sample Code Library
  • Software Patches
  • View All
  • Control Systems Configuration Tools
  • Procurement Specifications
  • ProposalWorks Proposal Builder
  • Global Short-circuit Current Ratings Tool
  • Integrated Architecture Builder
  • View All
  • Migration & Modernization
  • Lifecycle Status
  • Product Replacement Lookup
  • View All
  • Support Options
  • Search for Answers
  • Chat Online
  • Call Us
  • View All
  • My Inbox
  • My Favorites
  • My Subscriptions
  • View All
  • Chat History
  • Service Ticket History
  • Manage Your Favorite Answers
  • Field Service Request
  • View All
  • My Training
  • View All
  • Automation Fair
  • Process Solutions User Group
  • Rockwell Automation On The Move
  • Rockwell Automation TechEd
  • ROKLive
  • PACK EXPO CONNECTS
  • View All
  • Live
  • On-Demand
  • View All
  • Students & New Grads
  • View All
  • Hackathon Use Case for Manufacturing Optimization
  • Hackathon Use Case for Sustainability
  • Hackathon Use Case for Visual System Modernization
  • Hackathon Use Case for Dynamic Filtering
  • View All
  • 24toCode Event Recap - Winter 2019
  • 24toCode Event Recap // IT Internal Hackathon
  • Meet the 2019 IT Summer Interns
  • 24toCode Promo Video
  • Harbor View Plaza Ribbon Cutting
  • Check Your Blind Spots Mobile Tour at Rockwell Automation
  • Mechanic & Tool Apprenticeship at Rockwell Automation
  • Working at Rockwell Automation in Karlsruhe
  • Summer Internships at Rockwell Automation
  • The Intrapreneurial Skills Accelerator at Rockwell Automation
  • Makers Wanted
  • #LifeatROK w Katowicach
  • IT Summer Internship Program
  • #LifeatROK with Diogo
  • View All
  • Cisco
  • Endress+Hauser
  • FANUC
  • Microsoft
  • Panduit
  • View All
  • Our Focused Giving
  • STEM Education
  • Lifelong Learning
  • View All
  • Sustainability Report
  • Our Commitment to Diversity, Equity and Inclusion
  • Environmental, Health, & Safety
  • Ethics & Compliance
  • Global Supply Chain & Sourcing
  • Product Environmental Compliance
  • Quality Management Systems
  • Trust & Security
  • Workforce of Tomorrow
  • View All
Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
Blogs DistributorDistributor How to Buy EventEvent Events
Find Products by Our Brands:
Allen-Bradley FactoryTalk
Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
ProductivityProductivity Investor Relations
  • Literature LibraryLiterature Library
    Literature Library

    Access technical and commercial publications for hardware and software products, applications, services and solutions.

    PCDCProduct Compatibility and Download Center
    Compatibility & Downloads

    Find downloads including firmware, release notes, associated software, drivers, tools and utilities.

    KnowledgebaseKnowledgebase Support Center
    Knowledgebase

    Browse the database of questions and answers on a variety of products and technologies.

    Product ConfiguratorProduct Configurator
    Product Configurator

    Configure and select products rapidly.

    Software SubscriptionsSoftware Subscriptions
    Software Subscriptions

    One stop shopping for software and subscription services.

    2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
    Tools
    UserUser Sign In/Create an Account
  • User Account User
Tools
Literature LibraryLiterature Library
Literature Library
PCDCProduct Compatibility and Download Center
Compatibility & Downloads
KnowledgebaseKnowledgebase Support Center
Knowledgebase
Product ConfiguratorProduct Configurator
Product Configurator
Software SubscriptionsSoftware Subscriptions
Software Subscriptions
2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
Case Study
Recent ActivityRecent Activity

VIP Packaging Leads the Pack with Robotic Palletising Solution

Designing a new fully automated palletising line for a world-class packaging company required an innovative solution that integrated safety, automation and control

Share This:

LinkedInLinkedIn
TwitterTwitter
FacebookFacebook
PrintPrint
EmailEmail
Main Image

Challenge

  • To deliver a new fully automated palletising, strapping and stretching line that improves productivity, generates labour savings and adheres to occupational health and safety requirements

Solutions

  • CompactLogix™ was used to integrate control, safety and motion for the palletising line
  • PowerFlex® 4M provided effective motor control for conveyors
  • PanelView™ Plus 1000 operator interface incorporating a number of selection options and alarms
  • Integrated safety components
  • Fully customised robotic gripper for package handling

Results

  • Reduced labour costs - Automated solution delivered significant labour cost savings
  • Safety zone control - Provides integrated safety that allows plant to be shut down in one zone while the other is in operation Access to specific components for maintenance Minimises production downtime
  • Consistent quality control - Automated quality control system
  • Attractive ROI - Automating the palletising line resulted in labour savings, quality control and reduced running costs ROI approximately only 2 years

Palletising in any manufacturing plant presents many operational challenges from production efficiencies to safety considerations. This is particularly applicable to a company like VIP Packaging, a leading plastic and steel packaging company in Australia and New Zealand.

VIP Packaging manufactures extrusion blow-moulded and injection stretch blow-moulded high-density polyethylene (HDPE), polyethylene terephthalate (PET) and low-density polyethylene (LDPE) bottles.

The production facility manufactures packaging solutions for the food and beverage, personal care, household consumer and industrial chemical industries.

With clients that include many of the most well known household names in Australia and New Zealand, VIP Packaging is committed to innovation, quality and sustainability.

The production line at the plant predominantly palletises bottles used for shampoos and laundry detergents. To minimise manual handling and gain production efficiencies, VIP Packaging called on Machinery Automation & Robotics (MAR) to deliver a solution to automate their palletising production line.

Hands-free Palletising

The VIP Packaging plant transfers packaging bottles that are arranged in pallets in a predesigned format that is suitable for transport directly to clients. These bottles can range in size from 500 millilitres to two litres and are delivered wrapped with clear plastic stretch wrap to ensure the bottles stay in position when transported.

Adhering to occupational health and safety standards, improving productivity and generating labour cost savings were all important priorities for VIP Packaging. According to Geoff Biscaya, rigid containers general manager at VIP Packaging, “To remain competitive it was clear we needed to reduce labour costs by automating our downstream inspection, packing and palletising of our high volume blow moulding machines.”

Throughout this process there were three main palletising lines that would benefit from automation.

These include the packaging handling, the pallet handling and the stretch wrapping. The challenge ahead was to design a system that could automate the entire palletising line and deliver not only the cost savings, but also improve quality control and safety. After studying the operation of the VIP system, MAR presented a fully automated system including three robots, pallet dispenser, twin shuttle, three vision system, fully automated HMI, automated pallet strapping system and pallet stretching machine which were all controlled by one central motor control centre from Rockwell Automation.

In the VIP Packaging plant, plastic bottles are continuously transported on the conveyor to the palletising line where they are picked up by the robot and stacked in the pallet. Sensors are used to count the required quantity of bottles for each layer of packaging. Once a layer is complete, the robot picks up a plastic slip sheet and places it on top of the layer of bottles.

This process is repeated until the pallet is full; the robot then places a timber sheet on top of the pallet to keep the bottles in place. According to Merv Shirazi, project manager at Machinery Automation and Robotics, “The design of the grippers or claws on the robot arm was critical to the efficiency of the palletising process.”

“When the plastic bottles stand up, we needed to make sure that they were in correct position because if one bottle slipped or fell out of place, a domino effect could occur and hundreds of bottles could then fall which would not only create a safety hazard that would need attention, but it would also mean that the whole pallet would have to be rejected,” he explained.

To stop the bottles that are packed in the pallet from breaking or slipping, the pallet is then automatically wrapped in clear plastic. Each pallet is then transported by shuttle to the loading dock and the empty pallet is returned.

It's All Under Control

In any automated system, integration between the control and safety system is important but in a palletising line that is controlled by a single operator, complete integration is essential. PowerFlex® 4M drives were used to provide effective motor control for the conveyors and the entire robotic palletising system and was controlled by CompactLogix™.

According to Harish Ahuja, OEM account manager at Rockwell Automation, “The Rockwell Automation compact machine control platform provides cost-effective integration of a machine or safety application into a plant-wide control system because it integrates safety, motion, discrete and drive capabilities in a single controller, making it the most appropriate choice for this application.”

The operator workstation features a user-friendly PanelView™ Plus 1000 touch screen Human Machine Interface (HMI) which is easy to navigate and incorporates a number of selection options. In addition to the primary control for the system start and stop function, the HMI also includes programming for the manual control of conveyors, manual control of the robot gripper, shift production data, error reporting, robot control and access control for maintenance and cleaning.

“The programming of the system is simple and straightforward and it caters for a wide range of bottle design shapes and sizes. The control platform also includes integrated safety systems which deliver improved operator safety,” said Biscaya.

When moving to an automated system, operator safety was a key priority so with this in mind the system was designed with six separate safety zones that require no supervision. Parts of the plant were required to operate 24 hours a day, 7 days a week, which is why reliability and minimising downtime was very important to VIP Packaging. This was addressed by designing and building the line to allow access to specific components that wear over time in a particular machine, without having to shut down the whole plant during routine maintenance.

Installing a new solution generally requires a period of shutdown of the existing system while the new one is installed so the goal with this project was to keep this to a minimum and also to reduce the risk of any teething problems with the new solution. To achieve this, the new system was thoroughly tested off-site prior to installation.

“The complete system including cycle times and other parameters were factory tested off-site prior to installation so we could minimise the risk of downtime. This ensured that the installation progressed smoothly which was very important to our business,” said Biscaya.

Consistent Quality Control

Maintaining superior quality control is essential to VIP Packaging, who is known for packaging solutions that not only offer outstanding performance but also differentiate and enhance their customers' brand. Biscaya knew that automating their quality control systems would help them to maintain their reputation for superior quality packaging solutions and also introduce labour cost savings.

“With the help of MAR we were able to integrate vision systems that could identify a number of bottle faults and reject those bottles. This automated quality control system was more consistent than the human element which allowed us to lower the cost of each pallet through the associated labour savings and reduced packaging waste,” he said.

To confirm that the automated system was working effectively, the HMI system was programmed to monitor and sound an alarm to alert the operator if too many bottles were rejected consecutively.

Counting the Savings

“We are continuing to realise the many benefits that the new automated system is providing. It has met all of our key requirements by allowing us to reduce labour costs, while also improving quality control and safety. In addition, the solution has established a low base cost to run the plant over time which helps to improve our productivity and competitiveness,” said Biscaya.

The automation of the palletising line has resulted in significant labour savings, quality control and reduced running costs. The return on investment is approximately only two years, which will allow VIP Packaging to reap the rewards from the solution for many years to come.

Published September 25, 2015

Subscribe

Subscribe to Rockwell Automation and receive the latest news, thought leadership and information directly to your inbox.

Subscribe

Recommended For You

Loading
  • Technical Question
  • Chat Technical Support
  • Phone Support
  • Contact Sales
  • General Questions
  1. Chevron LeftChevron Left Home Chevron RightChevron Right
  2. Chevron LeftChevron Left Company Chevron RightChevron Right
  3. Chevron LeftChevron Left News Chevron RightChevron Right
  4. Chevron LeftChevron Left Case Studies Chevron RightChevron Right
Discover
  • The Connected Enterprise®
  • Create Your Account
  • Case Studies
  • Events
Information for...
  • Distributors
  • OEM
  • System Integrators
  • Encompass Partners
  • Investors
  • Career Seekers
Contact Us
  • General Questions
  • Technical Questions
  • Local Sales & Service
  • Pricing & Availability
  • Report Ethical Concerns
  • Customer Experience Survey
Site Information
  • Legal
  • Privacy Policy
  • Cookie Preferences
  • Terms of Use
  • Trademarks
Change Country Site SelectionChange RockwellAutomation.com site selection to a different country, region or language Change Country
Puerto Rico/English

Keep Updated With Us

Sign up to receive our latest headlines for free.

Stay Informed Now
Follow Us
BlogRockwell Automation's Blog
Copyright ©2021 Rockwell Automation, Inc.
Home