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One of the most important things you need to know before choosing a Case Packing robot for your factory is the type of robot you need. There are different types of robots used in warehousing and logistics. However, the robot types in this list are well suited for case packing scenarios.
Gantry robots are attached to a ceiling-mounted track and operate on a linear motion system, with movements along three primary axes: X (horizontal), Y (horizontal), and Z (vertical). They are known for their impressive payload capacity and reach, making them an ideal choice for case packing scenarios involving heavy products and larger cases. Their rigid construction ensures stability and precision when handling such items.
However, Gantry robots have inherent limitations when it comes to flexible motion. Their rigidity, while advantageous for lifting heavy loads and maintaining precise positioning, hinders their ability to perform tasks that demand dynamic or unconventional movements.
For example, some case packing operations require intricate packing patterns, such as nesting items in a box, or interlocking items within a case. Gantry robots may find it challenging to achieve these patterns due to their limited flexibility.
Articulated robots closely mimic the precision and dexterity of human arms. The robot arms often have 5 or 6 axes (or joints). This characteristic is invaluable in packing various products that demand accurate and delicate handling. Whether you're placing fragile items into cases, arranging products with specific orientations, or ensuring minimal product damage, articulated robots can replicate the fine control needed for these tasks.
In case-packing, there are instances where the robot needs to access tight spaces, reach around obstacles, or approach products from unconventional angles. Articulated robots' flexibility and multi-axis movement make them well-suited for such scenarios. They can adapt their arm configurations to navigate obstacles or reach into challenging areas within cases, ensuring complete and precise packing.
SCARA stands for Selective Compliance Assembly/Articulated Robot Arm. SCARA robots are more specialized than normal articulated robots, so they are not suitable for every application. However, what a SCARA robot lacks in flexibility, it makes up for in speed and precision. SCARAs move faster than Six-Axis robots because there are fewer joints involved.
While SCARA robots lack the full angular flexibility of Six-Axis robots, this limitation can be advantageous in certain case packing scenarios. It prevents unwanted movements or misalignment that could occur with overly flexible robots. SCARA robots maintain strict control over their movements, reducing the likelihood of errors.
In tasks that require precise positioning and minimal angular deviations, SCARA robots are preferable. They prevent unwanted tilting or rotation of products during packing, ensuring alignment and stability.
When choosing a robot for your factory, you’ll need to decide between fixed and mobile options. Each has pros and cons, so consider your specific needs and environment. For many factories, a hybrid approach with both fixed and mobile robots is optimal. The fixed robots can handle the bulk of high-volume packing, while the mobile robots deal with smaller batch packing in different areas. This provides maximum throughput and flexibility.
Fixed robots are stationary, and the cases are brought to them, usually via a conveyor belt. These are ideal if you have a dedicated packing area and high throughput.
Mobile robots have wheels, tracks, or other locomotion mechanisms that allow them to navigate the shop floor or warehouse. They move to the cases so they can pack at multiple locations. They’re a good choice if you want flexibility.
Production volume and speed requirements: The first and foremost consideration is your production volume and speed requirements. Different robots have varying speeds and payloads, so you need to ensure the robot you select can meet your production targets efficiently. It's also crucial to consider future scalability if your production needs are expected to grow. Here are some questions you can ask yourself:
Product variety and packaging complexity: Understand the range of products you handle and the complexity of your packaging requirements. Some case packers are better suited for uniform products with consistent shapes and sizes, while others excel in handling a diverse range of items.
For example, if you mostly handle delicate items like eggs, you need a robot with a vacuum end-effector to guarantee food safety. The end-effector is the part of the robot that grabs the item for packing. If your products vary significantly in shape, size, or packaging, opt for a robot with adaptability and versatile end-effectors. Here are some questions to help you pick the right robot:
Case sizes and types: Analyze the type of case or box you use for packaging. Ensure the robot can accommodate the dimensions and styles of cases you require. Some robots may have limitations on case sizes and trays or require customization for non-standard cases. Gantry robots are very large, and there is hardly any task that is too big for them, but there are tasks that can be too small for you to need a Gantry.
Integration with existing systems: Compatibility with your existing systems, such as conveyor belts, software, and control systems, is paramount. Choose a robot that can seamlessly integrate into your production line. Consider the ease of communication and data exchange between the robot and other equipment.
Ease of use and programming: Evaluate the ease of programming and operation. A user-friendly interface is crucial, especially if your staff has limited robotics experience. Look for robots that offer intuitive software and programming options. Complex tasks may require more advanced programming capabilities, so ensure your team is prepared for such challenges.
Maintenance and service: Consider the long-term maintenance requirements of the robot. Assess the availability of spare parts, as well as the manufacturer's track record in providing timely maintenance and support. Regular maintenance is crucial to keep your robot operating at peak performance.
Cost and return on investment (ROI): Calculate the upfront costs and ROI for your robotic case packer. It’s not unusual for a Gantry robot to cost as much as $50,000, but a SCARA’s purchase cost is less. However, gantries are sturdier and hardly need parts replacements as often as a SCARA. Also, estimate the time it will take for the robot to pay for itself through increased efficiency, reduced labor costs, and improved product quality. Before choosing a robot, consider these questions to estimate the cost and ROI:
Here are some top case packing robot manufacturers for you to choose from:
ABB offers a comprehensive lineup of industrial robots designed to enhance productivity and efficiency across industries. Their robots are utilized in case packing applications across various sectors, including pharmaceuticals, logistics, and consumer goods.
ABB robots are celebrated for their speed, precision, and adaptability. They often feature intuitive programming interfaces and advanced vision systems for improved product handling and quality control.
KUKA AG is a leading global provider of robotics and automation solutions. They specialize in industrial robots and automation systems for a wide range of industries. KUKA offers a diverse portfolio of robots suitable for case packing applications.
Their robots are used in various sectors, including automotive, electronics, and e-commerce, for efficient and precise case packing.
KUKA robots often feature advanced control systems and software that facilitate seamless integration into existing production lines.
FANUC robots often feature user-friendly programming interfaces and robust safety measures, making them accessible and safe for operators. They also offer a diverse range of payload capacities and reaches to accommodate various case packing requirements. Their robotic case packers work with RSC cases and display cases.
We wouldn’t be doing you justice if we didn’t mention our wide range of robot solutions. Standard Bots is a US-based robotics manufacturer. Our RO1 six-axis robot combines the flexibility of an articulated robot with the speed and precision often found only on a SCARA robot. They are a good choice to start your automation process because of their competitive pricing and cost-effective solutions.
Selecting the right Case Packing robot is a complex decision that requires careful consideration of your production requirements, safety concerns, and long-term goals. By thoroughly assessing each of these considerations, you can make an informed choice that aligns with your business objectives and ensures a smooth and efficient case packing process.
Are you ready to invest in a case-packing robot? RO1 by Standard Bots is a cost-effective robot designed for factories of all sizes. With its unique subscription model, our users never have to worry about software updates or hardware issues, ensuring that RO1 is always in top working order. RO1 is designed to be compatible with a wide array of accessories, allowing users to customize and enhance its functionality.
You can book an onsite trial for 30 days to test how RO1 integrates with your factory. Speak to our solutions team today.