Blog : Case studies that show how palletising can reduce bottlenecks.
Palletising Tech to Improve OEE
In an era of rising costs, ongoing labour shortages and heightened consumer demands, FMCG manufacturers often face a daunting challenge: how to produce more products, safely, and with fewer resources.
Owing to the historically higher costs and large footprints of automated palletising systems, this end of the packaging line is often overlooked when improvements are being considered. Production line bottlenecks—often caused by outdated palletising systems—account for 20-30% of annual productivity losses.
The good news?
Modern palletising solutions can quickly resolve these inefficiencies and improve Overall Equipment Effectiveness (OEE), delivering measurable ROI within months.
Here are three recent examples of how the latest palletising technology is transforming businesses across the FMCG industry.
The common element for three of these solutions is that palletising no longer needs to be a bespoke custom solution for each application. Advances in robotics and control software mean that palletising ‘products’ are now available. These palletising products have many benefits, including lower cost, shorter lead times, smaller footprints and less technical deployment risk.
Case Study 1:
ESCALATING DELAYS
The Challenge
A mid-sized food manufacturer faces escalating delays due to manual palletising. Its line operators struggled to manage heavier cases efficiently, resulting in workplace injuries, costly overtime and recurring production bottlenecks.
The Solution
The INSTANT ROBOT PALLETISER i35, an all-in-one palletising system designed for ease and efficiency.
Key features included:
- High payload capacity: Able to handle cases up to 34 kg at 12 cycles per minute, or 24 cases per minute for 17 kg cases.
- Advanced software: Multi-variable case pick-up software enables the robotic arm to select one or two cases at a time, optimising pallet layer patterns dynamically.
- Plug-and-play design: Operators set up the system and any new SKU layer patterns in under five minutes with no technical expertise required.
- Continuous operation: Dual-pallet configuration ensures uninterrupted production as pallets are swapped out.
The Results
Six months after implementation, the manufacturer saw a 15% increase in productivity and a 40% reduction in manual labour costs. Within 10 months, it had achieved ROI.
The company also saw the benefits for its team, with improved employee job satisfaction due to reduced injury rates and risk, and stress, thanks to a production line that operates seamlessly during peak demand periods.
Case Study 2:
SPACE RESTRICTIONS, WASTE CONCERNS
The Challenge
A beverage manufacturer needed a compact solution to de-stack pallets, palletise and then stretch-wrap products while addressing inefficiencies in film usage and handling either shelf-ready cases or shrink-wrapped trays.
ROBOPAC PALWRAPP, a space-saving system with advanced features such as:
- Integrated palletising and wrapping: Eliminates the need for separate equipment and pallet conveying, saving valuable factory floor space.
- CUBE Technology®: Optimised film usage reduces stretch film costs by up to 55% with variable pre-stretch and containment force settings.
- High-speed operation: Handles up to 50 cases per minute, with a capacity for up to three layers per minute and layer weights of up to 350 kg. Pallets are progressively wrapped as each layer is completed, reducing total cycle time.
- Layer forming palletiser: Ensures nearly all secondary pack formats can be accommodated.
- Gentle product handling: Ensures the safety of fragile products through precise placement and wrapping mechanisms.
The Results
Within three months, all SKU case formats were being successfully palletised with zero LTI (Lost Time Injury) concerns. The integrated solution reduced forklift movements and also made logistics safer as there was extra freed-up floor space. Operators appreciate the intuitive controls and the system’s compact design fits seamlessly into their existing layout.
Case Study 3:
LABOUR INTENSIVE, ERROR-PRONE
The Challenge
A small-to-medium winery struggled with manual palletising that was slow, error-prone, and labour-intensive. Manual palletising becomes problematic during seasonal demand spikes and when managing diverse product SKUs. Heavy twelve-bottle cases are a significant manual strain injury risk.
The Solution
The INSTANT COBOT PALLETISER, a lightweight, plug-and-play mobile system. Key features include:
- Quick deployment: Fully portable and ready to operate with just 240V power and air.
- High capacity: Capable of handling cases up to 28 kg, or two 14 kg cases simultaneously.
- User-friendly interface: The 13’’ touchscreen wizard allows operators to input case dimensions and pallet patterns with zero programming or technical skills.
- Safety-first design: Integrated zone scanners ensure safe operation at speeds above five cases per minute.
- Dynamic adaptability: Smart software automatically adjusts for barcode placement and optimised pallet stability with interlocking patterns.
The Results
Within six months, the manufacturer reports a 20% increase in productivity and a 25% reduction in labour costs. Seasonal peaks are managed effortlessly by relocating the mobile palletiser to different areas of the factory. With an ROI achieved in just nine months, the company reduces workplace injuries and improves overall line efficiency.
Case Study 4:
MULTIPLE SKU INEFFICIENCIES
The Challenge
Leading Australian producer of margarine and spreads, Nuttelex, experienced inefficiencies due to their existing palletising system's inability to handle multiple SKUs concurrently. This limitation resulted in frequent stoppages for manual changeovers, increased labour costs, and reduced overall equipment effectiveness (OEE).
The Solution
Foodmach's Robomatrix® Multi-SKU Palletiser, featuring:
- High-Speed Multi-Line Handling: Capable of palletising multiple products to multiple locations simultaneously, effectively managing diverse packaging styles, shapes, and sizes.
- Advanced Pattern Programming: Utilising proprietary Robowizard® software, operators can create and modify pallet patterns via a user-friendly drag-and-drop interface, facilitating rapid changeovers without the need for specialised technical skills.
- Modular Design: The system's modularity allows for the addition of palletisers, sharing the same inbound and outbound pallet handling, providing scalability for future growth.
The Results
Nuttelex reported reduced changeover downtime, leading to a boost in production efficiency. The automation of its palletising process meant it was less reliant on manual labour, reducing its labour costs. And the system's flexibility allowed Nuttelex to respond swiftly to market demands without major operational disruptions.
By adopting Robomatrix MULTI SKU, Nuttelex overcame existing operational challenges and positioned itself for scalable growth in a dynamic market.
No Capital? No Problem.
Get palletising now with Lease2Buy.
Foodmach understands that CAPEX can be a barrier. That’s why we offer Lease2Buy, enabling you to spread costs over two to five years with low interest rates and no capital investment required. With this flexible payment plan, you can access the latest palletising technology and see return on investment before your payments are complete.
Whether structured as a chattel mortgage, rental, or finance lease, Lease2Buy provides a straightforward plan with no balloon payment, allowing you to upgrade your production capabilities without depleting capital reserves. This approach enables you to invest in advanced equipment—such as palletisers, conveyors, and stretch wrappers—while preserving working capital for other strategic initiatives.
Additionally, Lease2Buy offers potential tax and accounting benefits, depending on the chosen financing structure. By converting capital expenses into manageable operating expenses, you can achieve positive cash flow from day one, making it a smart investment in your company's future.
It’s fast to set up and can improve your cash flow immediately.
Think Palletiser, Think Foodmach
From low to high speed, mechanical to robotic, Foodmach has a palletising solution for every application. Our systems are intuitive, efficient, and designed to maximise Overall Equipment Efficiency and ROI.
Or, think beyond palletisers to our end-to-end range of packaging technology from the world’s finest, all of which come with Foodmach’s 50+ years of OEE expertise.
