Customised palletiser software replaces manual process

KUKA has developed an innovative software control system that has boosted the efficiency of a palletising system being used to handle boxes of snacks at KP Foods' factory in Billingham, Cleveland.

The KUKA PalletTech software is specially designed to streamline the round-the-clock palletising operation. This comprises conveyors and a pair of 30m Güdel gantries fitted with bridges and vacuum gripper tools that can lift up to three boxes at a time and make as many as three separate drops onto the pallets. Furthermore, the system can work with a range of box sizes and palletise to 32 different locations. It can also handle empty Chep pallets.

Each gantry has its own KUKA control panel that enables the operator to monitor the palletising process; this was previously performed by hand at the end of each production line.

Maximising efficiency

Paul Richards, general sales manager at KUKA Automation + Robotics, explains the project requirements: "While the gantry system offered the most cost-effective, automated solution that could be accommodated in the available space in the factory, the challenge for KUKA was to adapt its PalletTech software, which is designed for use with robotic palletising operations.

"One of KUKA's top software developers, Ed Volcic, together with KUKA's robotic palletising expert, Thomas Michel, set about creating a bespoke program that could transform a time-consuming, manual task into a high-speed and efficient operation."

The software program was developed from a series of complex calculations that had to take into account varying box patterns, box sizes, pallets and slip sheets. Members of KP Foods' engineering team also visited KUKA's global sales centre in Gersthofen, Germany, to view trials of their products being palletised on a demonstration gantry.

KUKA Automation + Robotics supplies a wide range of robots and automated production systems specifically for order picking and assembly, palletising and handling applications.