Case Study: Laning sausage products to maximise the efficiency of pick-and-place robots

Client Background

A prominent player in the food manufacturing industry, our client specialises in producing a wide range of high-quality sausage products. With a commitment to efficiency and quality, the client sought to enhance their production process and reduce labour costs while maintaining the integrity of their products. 

Challenge

The client’s existing production line involved manual handling and packing of sausage products, which required significant labour and was susceptible to inconsistencies in spacing between products. The lack of uniform separation made it challenging for their pick-and-place robotic system to recognise and handle the sausages accurately. Inefficiencies in product handling led to decreased output and increased operational costs. 

Solution

At VCSP, we have a proven track record in innovative automation solutions tailored to the food manufacturing industry. Recognising the client’s challenge, our team of experts proposed a four-stage landing system designed to address the spacing issues and enhance the efficiency of the pick-and-place robotic system.

Implementation

1.     Assessment and Design: Our engineering team comprehensively assessed the existing production line. Based on the analysis, we designed a four-stage landing system that created consistent separation between each sausage product. This new system allowed the pick-and-place robotic system to identify and handle individual sausages accurately.

2.     Customised Conveyor System: We custom-engineered a specialised conveyor system that incorporated four distinct landing stages. Each stage was designed to provide controlled and precise spacing for the sausage products as they moved along the conveyor.

3.     Integration with Robotic System: The four-stage landing system was seamlessly integrated with the client’s existing pick-and-place robotic system. Our engineers worked closely with the client’s team to ensure smooth communication and synchronisation between the landing system and the robotic operations.

4.     Testing and Optimisation: Rigorous testing was conducted to validate the functionality of the new system. Adjustments were made to ensure optimal spacing accuracy, allowing the robotic system to consistently recognise and handle the sausages with precision

Results

The implementation of the four-stage landing system yielded remarkable outcomes for our client:

• Labour Cost Reduction: By removing the need for manual spacing and handling of sausages, the client could eliminate four operators from the production line, resulting in significant labour cost savings.
• Enhanced Efficiency: The new system improved the overall efficiency of the production line by eliminating spacing inconsistencies and minimising the risk of product jams.
• Increased Output: The precise spacing created by the landing system allowed the pick-and-place robotic system to operate at maximum efficiency, leading to increased output and throughput.
• Cost Savings: The reduction in labour costs, increased efficiency, and improved output translated into substantial cost savings for our client, contributing to a healthier bottom line

Conclusion

Through the strategic implementation of a four-stage landing system, VCSP – the author of this case study – successfully addressed the client’s challenge of achieving consistent product separation for their pick-and-place robotic system. The automation solution removed labour-intensive tasks, significantly improved production efficiency, and reduced operational costs. This case study serves as a testament to VCSP’s commitment to delivering tailored, innovative solutions that drive tangible results for our partners in the food manufacturing industry.