The client is a leading company in the production of food doypacks — resealable flexible plastic pouches mainly used for packaging liquid, semi-liquid, or granular food products, ensuring practicality and optimal preservation of the contents.

With a headquarters in Northern Italy, several national production units, and a well-established presence in the European market, the company boasts extensive experience in the food packaging sector. In recent years, faced with the growing demand for increasingly sophisticated packaging solutions and the competitive pressure of the market, the company recognized the need to further enhance efficiency, productivity, and accuracy in order to maintain and strengthen its position in a highly competitive and constantly evolving landscape.

The challenge

The key objective assigned to us was to automate the delicate process of handling stacks of food doypacks coming out of the packaging machine, which simultaneously produces four parallel and overlapping stacks. The challenge was to simultaneously pick up these four stacks, accurately verify their position, and precisely insert them into pre-arranged plastic crates with dedicated separators to ensure an orderly and stable arrangement. Specifically, the solution had to meet the following requirements:

• Absolute precision in product placement
• High production and operational speed
• Drastic reduction of manpower assigned to repetitive tasks
• Optimization of the available space within the facility

The solution

We addressed the challenge with a highly technological and customized solution, designed after thorough analysis and on-site inspections:

• High-performance anthropomorphic robots working simultaneously to ensure precision and speed
• Automated positioning system for the stacks to streamline and accelerate operations
• Fully automated crate handling, from initial loading to final retrieval of filled crates
• Advanced supervision software to ensure real-time control of every phase of the production process