From manual to automatic set-up

CO-RO is a major producer of fruit-based beverages and do-it-yourself ice cream, delivering approximately 180 million units globally each year. Due to the growing demand for Sun Lolly ice cream, there is a need to produce even more ice cream than before. This is one of the reasons why CO-RO has upgraded their existing "End of Ice Packaging line" by fully automating the system with a solution provided by REO-PACK.

Before upgrading to the new system, the process involved machines over 20 years old and a resource-intensive facility with many manual functions, especially regarding pallet handling. 

This manifested in numerous labour-intensive processes, both in terms of manually setting up the robot for the current production by selecting pallet type, box type, and the number of layers on the pallet, and when the robot needed to be fed with pallets and the removal of pallets. CO-RO also faced a challenge with insufficient buffer capacity on the pallet conveyors, resulting in time-consuming back-and-forth movement of pallets. Empty and finished pallets also had to be transported to and from the robot, then to and from the stretch wrapper, application of top film, securing the film to the pallet, and replenishing with empty pallets. Additionally, pallet labels had to be manually retrieved from production papers and printed before being manually applied to the pallets.

The many manual tasks naturally impacted the working environment, which was one of the reasons for this upgrade. With a desire to increase capacity, eliminate heavy lifting and monotonous repetitive work, as well as improve poor working postures in general, a decision was made to invest in a fully automated system. REO-PACK was chosen for the project as they could manage all aspects of the project. However, the robot in this solution was supplied by another vendor, as CO-RO wanted to use their previously familiar robot supplier.

In the packaging department of the Lolly section, a fully automated system has been installed with pallet magazines for each of the three pallet types, a ¼-pallet crane capable of placing 4 ¼-pallets on top of a Euro pallet, a couple of transfer carts, and buffer conveyors for waiting pallets. Additionally, the system includes a stretch wrapper with an integrated top film applicator, a new label printer for fully automatic pallet labeling at variable heights, and finally, more buffer conveyors for finished pallets. The automation throughout the system has been upgraded so that all system components, via D365 and MES, are now set up fully automatically for production through the current job on the line. This job contains all data about pallet type, box type, wrapping patterns, and all other processes in the packaging department.