In the dynamic world of packaging and industrial automation, the demand for increasingly flexible and efficient solutions continues to grow. At Barcelona Packaging Hub, we are pleased to share case studies that define new benchmarks in the industry. Today, we present a standout case study featuring Xolertic, a Hub member, that showcases how collaborative robots are transforming end-of-line automation, even in the most challenging environments.
About Xolertic
Xolertic was formed through the strategic alliance of Sinterpack and Prodec, two companies with more than 60 years of combined experience. This partnership has positioned them as experts in integrated end-of-line automation solutions, including case packing, palletizing, AMRs, and of course, collaborative robots. With operations in Spain and India, Xolertic focuses on enhancing production efficiency, safety, and adaptability through advanced technologies.
The challenge: complex palletizing in constrained environments
Xolertic tackled a challenge presented by a major international client in the food sector. With over 600 product references and distribution to more than 15,000 retail points, the need to automate palletizing across multiple lines was pressing. The environment posed additional constraints: limited space, high variability in formats, and the need to maintain high throughput. These factors ruled out traditional industrial robots. Moreover, scalability was essential to allow future technology integrations.
The particularities of the environment made the situation more complex: limited space, a high variability of formats, and the pressing need to maintain high production levels. These conditions made the implementation of traditional industrial robots at the end of the line unfeasible. Additionally, it was crucial for the solution to be scalable, allowing for the integration of new technologies in the future.
The innovative solution: 12 UR20 collaborative robots
To meet the challenge, Xolertic implemented a compact and flexible solution using 12 UR20 collaborative robots from Universal Robots. Their safe human-robot interaction design and high payload capacity made them ideal for tight spaces and variable box formats.
Each palletizing cell, operated by a collaborative robot, is connected to a centralized control system that coordinates the entire process. On higher-speed lines, additional safety features such as scanners and fencing enable switching between collaborative and industrial modes based on operator presence.
An intuitive HMI interface allows operators to easily modify palletizing parameters such as the number of layers or stacking height, streamlining daily operation and reducing changeover times.
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Results: enhanced efficiency and safety
Xolertic’s solution brought measurable and impactful benefits to the client. Key advantages of the collaborative robot system include:
- Higher productivity and efficiency: Cycle times were significantly reduced, and manual palletizing was eliminated, optimizing resources through the speed and consistency of the cobots.
- Superior precision and quality: Accurate stacking minimized errors, resulting in greater stability and uniformity of the pallets delivered by the collaborative robots.
- Safer and more ergonomic work environment: The collaborative nature of the robots reduced physical strain and labor risks for operators, promoting a healthier and safer workplace.
- Operational flexibility: The system quickly adapts to multiple product formats, offering high versatility and an exceptionally low learning curve for the collaborative robots.
- Technological scalability: The solution is ready to integrate future technologies like AMRs and automated systems without the need for complex structural redesigns, ensuring long-term ROI.
The end client expressed high satisfaction with the improved organization and condition of delivered products, highlighting the positive impact of Xolertic’s solution across the entire value chain.
This case study from Xolertic is a clear example of how innovation and technological adaptability can solve complex challenges in the packaging sector, delivering solutions that significantly improve efficiency, safety, and competitiveness.
At Barcelona Packaging Hub, we celebrate these advances that are propelling the industry toward a more automated and efficient future.