Case Study
Robot palletizing system for Griffins
Challenge
Additionally, Griffins were having crushing problems on their conveyors. Boxes of all sizes were jostling for position and the smaller, more fragile cartons were getting crushed. In some cases, boxes would push each other off an overhead conveyor, which was a safety issue as well as a product loss problem. Workers were often up and down ladders clearing jams.
Solution
PHS Innovate was the automation supplier selected to supply the new palletizer solution for Griffin’s factory. We designed a SAP-compatible system utilising four ABB robots and integrated stretch wrapping and labelling. Our proposal also included an upgrade to Griffins’ conveyor systems, to help with back pressure and product line control.
The new palletizer system was installed while the old system was still running, to enable a staged changeover. Our robots were equipped with standard mechanical gripping heads, which have the versatility required for Griffins’ diverse product range. Compared to Griffins’ old system, this method of holding cases was a significant improvement.
The final installation was achieved over two weekends, to ensure minimal impact to production at the factory. Initially, half the production line was directed to the new palletizer system. After a few weeks, when it was clear that everything was running smoothly, total production was directed to the new solution and the old palletiser was decommissioned. The new palletizer solution is connected to Griffin’s SAP management system for improved stock reconciliation.
As part of the new palletizing system, PHS Innovate provided a zero pressure accumulation conveyor that enables different case sizes and weights to accumulate safely. This upgrade minimises the risk of jamming and damage to the product.
Steven Cope
Capital Investment Manager
Griffins Foods
Fact box
- Nine lines can be palletized across 4 x ABB IRB660 180kg payload robots
- Robots can palletize cases ranging from 240mm to 600mm in length
- Robots are equipped with a two-zone gripper head that can pick up multiple cases per pick and split placement to form complex patterns quickly
- Wrapping capacity of up to 80 pallets per hour
- SSCC labelling integrated with Griffins’ SAP system