Robots to the rescue? Syntegon to premiere pick-and-place platform at FachPack as automation plugs labor shortages

11 Jul 2022 --- Syntegon is preparing to unveil a new robotics pick-and-place (RPP) platform at FachPack in Nuremberg, Germany (September 27-29). The company says the COVID-19 pandemic has significantly accelerated the mega-trend toward automation amid labor shortages and higher productivity demands.

The RPP platform complements packaging lines by managing product handling or feeding. The solution will be on display as part of a turnkey system in combination with the SVE 2520 DZ vertical bagger and the Kliklok ACE carton erector at the trade show.

“Many manufacturers replace manual work steps with fully automated solutions. Pick-and-place robots support them in reaching their production targets with high efficiency and quality levels while minimizing product loss with gentle handling solutions,” Andreas Schildknecht, product manager for robotics at Syntegon, tells PackagingInsights.

“Further, robots enhance food safety as they minimize contamination risks by avoiding contact between operators and products.”

“Automated solutions will gain importance in the future because they help manufacturers to enhance their production flexibility. They can handle a variety of products and packaging formats – even random product streams – gently, are easy to clean and ensure reliable and efficient processes.”The robotic pick-and-place platform will be on display at FachPack as part of a turnkey system in combination with the SVE 2520 DZ vertical form, fill and seal machine and the Kliklok ACE carton erector for packaging pistachios.

Overcoming labor shortages
A common concern with the rise of robotics and automation is a potential lack of jobs for humans, but Schildknecht highlights that manufacturers are currently more concerned with labor shortages.

“Shortages of qualified labor is one of today’s most pressing challenges, and the pandemic fueled this issue even more. As a result, many food manufacturers turn to automated solutions and robots to replace manual work processes and cope with the lack of labor,” he explains.

“Robots take over monotonous and tiring tasks while operators may concentrate on more complex work instead, helping manufacturers to realign their labor force.”Syntegon machines process doy bags made of conventional materials but can also handle paper-based alternatives with ease.

Pistachios in doy bags
The company will demonstrate an integrated system solution for packaging pistachios at booth 1-204. The SVE 2520 DZ vertical form, fill and seal machine weighs MagNuss brand pistachios before packing them into doy bags. The highly flexible machine also processes all other common bag formats.

Meanwhile, the RPP platform picks up the doy bags, which are transported flat, positions them correctly and places them five at a time upright in cardboard trays that have been preformed on the Kliklok ACE.

The ACE covers both glue closure and glueless lock-style closures, providing sustainable options for different carton formats. The individual components of the exhibited line can be configured flexibly, giving manufacturers many options to respond to changing market trends with a wide range of packaging styles, formats and materials.A coffee pack made from recyclable monomaterials processed on the PMX machine.

Seamless integration
Syntegon will also demonstrate its system’s competence with the Elematic 2001 wraparound case packer, now also available with a Beckhoff control system in Europe. As the solution can be seamlessly integrated into vertical and horizontal systems, manufacturers can add a Syntegon case packer to their packaging lines, increasing the level of automation in their production.

Fast, tool-free format changes and more than 100 case designs allow manufacturers to respond quickly to changing market needs with the Elematic case packer. Additionally, all Elematic machines can reliably produce sustainable cases from recycled cardboard or grass fiber corrugated board.

Eco-friendly material goals
By the end of 2022, Syntegon aims to make all its machines for food packaging capable of processing environmentally sustainable materials.

“We’re already thinking about tomorrow: our Kliklok ACE carton erector, for example, creates paper trays for cookies, offering an attractive alternative to conventional plastic trays. And also the exhibited SVE processes not only plastic but paper-based materials into pillow bags for frozen foods, as well as stand-up bags or doy bags for dry foods,” says Torsten Sauer, project manager for sustainability at Syntegon.

In 2021, Syntegon presented new concepts for structured paper pods and blisters formed on the TPU form, fill and seal machine. A year on, the company has announced a cooperation with contract packer Truvant, who applies the solution for various customers. Visitors to FachPack can experience the paper solutions at the company’s booth.

Syntegon will also exhibit new sustainable coffee packaging made of monomaterial that can be processed into recyclable bags on the new PMX packaging machine.

By Joshua Poole