Flexible Packaging Lines: Robotics for Short Runs

The food and beverage industry is moving toward mass customization — smaller batches, faster changeovers, and frequent product launches. Traditional packaging automation can’t keep up. Enter flexible robotics: adaptive systems that reconfigure in minutes, not hours.

The Short-Run Challenge

SKU proliferation has forced producers to handle multiple packaging formats daily. Manual retooling consumes valuable uptime, and each delay affects freshness and yield.

Key Enablers of Flexibility

• Quick-change tooling: Magnetic or pneumatic grippers swap in under 60 seconds.
• Vision-guided robotics: Automatically detect and adjust for package size or orientation.
• Digital twins: Simulate recipe or layout changes before applying them physically.

Case Example: Snack Packaging Plant

A packaging facility deployed cobots with plug-and-play tooling. Recipe changes were handled from the HMI, cutting changeover time from 45 minutes to 8 minutes and boosting OEE by 12%.

Operational Tips

• Integrate MES triggers for automatic robot recipe download.
• Use smart conveyors that adjust width and height profiles automatically.
• Standardize end-of-arm tools for multiple packaging SKUs.

Related Articles

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• Allergen Control with Sensors and Software
• Digital HACCP: Turning Compliance into a Dashboard

Conclusion

Flexible robotics allow food manufacturers to meet consumer demand without sacrificing efficiency. When robots and MES work together, short runs become profitable — not painful.