achievements
Packer & Pal systems provide a fully automated end-to-end end-of-line solution that combines cases forming, robotic case packing, weighing, labeling, and palletizing.
Designed to meet the high standards ofthe cosmetics industry, this cell guarantees a production rate of up to 150 products per minute.
Thanks to its high flexibility, it can handle both individual bottles (from 100 mL to 1 L) and batches wrapped in shrink film, ensuring maximum productivity in a compact footprint.
Full automation of the end-of-line process, from filling cartons to final palletizing, including automatic management of divider sheets.
High-speed batch processing capable of handling high volumes (up to 150 vials per minute).
Centralized control of the line via a single, user-friendly HMI accessible to operators.
MSD risks and physical strain: Completely eliminates the repetitive manual handling of cases and end-of-line palletizing.
Traceability and Non-Conformity: Mitigates the risk of shipping errors using an inline weighing module (checkweigher) and an automatic label applicator with label presence detection.
Downtime Management: Reduces the time required to diagnose breakdowns using an onboard "dashcam"-style camera system that records the moments immediately before and after a malfunction.
Complexity of format changes: Eliminates lengthy downtime through the use of 3D-printed format parts and an intuitive user interface that requires no robotic programming skills.
cases preparation cases A mechanical forming machine prepares the boxes with the bottom sealed using tape (with a 1,500 mm-long tape dispenser).
Product grouping: Bottles or bundles arrive on a dual-lane conveyor equipped with a motorized divider to distribute the products to the batching stations without causing sudden congestion.
Automated packing: Two loading robots equipped with gripper clamps pick up the batches and place them into the cases.
Sealing and Inspection: The cases sealed from the top (using controlled tape) and then pass through a dynamic weighing station to verify the accuracy of their contents.
Traceability labeling: A "print-and-apply" label applicator applies the identification label to the case, which is immediately validated by a presence sensor.
Palletizing: A 6-axis articulated robot picks up the cases and places them on pallets (EURO or US) while automatically inserting cardboard dividers between the layers.
Output: Up to 150 products per minute.
Footprint: 12 meters long by 11 meters wide for the entire unit (L-shaped layout).
Types of products processed: round or square bottles, sold individually or in shrink-wrapped packs ranging from 100 mL to 1 L.
Accepted materials: Plastic bottles, corrugated cases and cases .
Format changeover time: Fast, facilitated by the HMI using a simple RFID tag and minimal tooling.
Compliance / Standards: Optimal security with enclosed protective enclosures (tempered glass doors) and the IXON module for cybersecurity (VPN).
Cosmetics
Exactly. The input grouping module and robotic grippers are designed to seamlessly handle individual bottles (ranging from 100 mL to 1 L) as well as pre-packaged batches wrapped in shrink film. The motorized divider adjusts the distribution based on the format currently in production.
Cybersecurity is a top priority. We use an "Edge Gateway" router (IXON) that creates a robust physical and software barrier (firewall) between the machine network (OT) and your factory network (IT). The connection for remote support is established via an encrypted VPN, ensuring that no external intrusions can access your data.
No. Our philosophy is to make robotics accessible. The Android-based Human-Machine Interface (HMI) is extremely intuitive and offers step-by-step guidance for format changes, eliminating the need to rely on a process engineer. In addition, all documentation is built directly into the machine.
Contact UNISTA for a customized assessment.
