Agile automation for multiple formats

ALH Group Integral Pack Solutions, headquartered in Polinyà (Barcelona), specializes in handling, packaging, labeling, assembly, and case packing services, primarily for perfumes and cosmetics. Its business model emphasizes flexibility, diversification of formats, and rapid adaptability for clients in the cosmetics industry who require efficient and reliable solutions.

A single solution for a wide variety of package sizes

ALH faced the challenge of handling a wide variety of cardboard box sizes on its palletizing line, within a limited space. It needed a solution that would provide a single system capable of adapting to multiple formats efficiently, without requiring multiple separate installations, and maximizing the use of available space.

Solution

To address this challenge, VMSystems, a specialized systems integrator, developed and implemented a comprehensive automation solution based on Yaskawa technology, installing a robotic cell at ALH consisting of three HC20DTP Floor collaborative robots, controlled by the YRC1000 controller with a Smart Pendant. Each robot is configured to work with two different production lines, allowing it to handle different product formats without changing the system. The cell also includes an insert placement function, enabling the automatic palletizing of boxes in various formats quickly and accurately.

Benefits

Format versatility: a single system capable of adapting to multiple cardboard box configurations.
Space optimization: thanks to the collaborative multi-line design, the need for multiple independent cells is reduced.
Simple self-programming: the use of the Smart Pendant allows the operator to configure future formats without the need for extensive reprogramming.
Increased productivity: two simultaneous production lines per robot allow for increased throughput without duplicating the infrastructure.
Automation of palletizing and interleaving: improved stacking quality, reduced manual errors, and process consistency.

Results

Thanks to the integration carried out by VMSystems, ALH has succeeded in automating the palletizing of cardboard boxes with a wide variety of formats in a compact space using a single system. With three robots working in parallel and the ability to self-program new formats, ALH has achieved: