Robot Line for 25 g. sausage products

ROBOT SYSTEM for self-service packaging of trays

The first robot solution was developed from the FPA for the final packaging of finished, filled trays.

It was delivered and put into operation just one year after the FPA was founded.

The packaging system takes the fully labeled trays and checks the labels for the correctness of the information. A 6-axis robot then picks up the trays and places them in the corresponding empty cardboard boxes according to the specified packing pattern.

The filled box is then fed into an existing elevator as a stacking unit of 4. The system was designed for high flexibility and is able to process different sizes of cardboard boxes and trays in a pure manner.

After the design and production phase, the system was delivered and put into operation at the beginning of April 2022. As is often the case with new developments, some of the process and reliability of the gripper system had to be optimized until everything worked smoothly.

The system contains two camera systems at the inlet of the cell to monitor and check the printing and position of the labels. Among other things, the correct placement and the order number, including the consistency of the label lettering, are checked.

The system achieves an output of 60 packs per minute. A packaging solution for fresh meat trays with an output of > 80 packs per minute is currently being developed on a similar basis, and will be implemented at a maximum width of 600 mm.

LOOPCUT - for the automatic packaging of fine salamis

This system was implemented in July 2021 by he FPA for the automatic separation and packaging of fine salami from the smoke cart into the flow pack system. The system was delivered and put into operation in April 2022.

The LoopCut was designed to automatically cut off sausage products that are hanging on a smoke skewer for drying and ripening and to automatically package them in the flow pack system.

The operator of the packaging machine uses a lifting aid to lift the smoke sticks with the product chains out of the smoke cart and hangs them in the empty buffer section. Up to 24 smoke skewers are temporarily stored in this buffer.

Optionally, the smoke sticks can also be automatically removed from the smoke cart using a 6-axis robot and hung in the buffer section.

The kinematics of the LoopCut picks up a full smoke skewer and feeds the products into a separating device. A light barrier checks the correct position of the products and the product centering fixes the salamis in place. A knife is then moved between the plastic strips in this clamping device using a toothed belt and cuts the products off the smoke stick.

A conveyor belt takes the products lying parallel on the belt to the packaging machine.
Once there, a funnel above the conveyor chain of the flow wrapping system takes over the individual salamis, registers a free area between the carriers and lets one product after the other fall into the feeder of the flow wrapping system.

The system can be used universally. If there is a major deviation in caliber or if the product length changes, small mechanical adjustments must be made to the LoopCut.
The performance of the system depends on the length and caliber of the products or the number of products on the smoke sticks. This means that a maximum of 80 products per minute can be packaged automatically.

PORTCUT 80 - CUTTING SAUSAGE PRODUCTS

The FPA PortCut 80 for self-service products cuts raw, boiled and cooked sausages. The system cuts product sizes from 35 up to 80 mm caliber with a length of 180 - 400 mm.

The cutting angle of the cutter can be manually adjusted continuously from 45 - 90 degrees. A simple plug-in system allows the knife to be changed in just a few seconds. The very narrow surface of the blade leaves a much lower number of CFU (colony forming units) on the cutting surface compared to cutting with a conventional knife or a circular knife.

FUNCTIONAL PRINCIPLE

The cutting process with the PortCut 80 takes place vertically using a servo drive. The products are held in position by hold-down devices mounted above the transport line.

The exact center of the product is determined with a 2D camera system when it enters the knife area and positioned directly in line with the knife. Thanks to the electrically operated knife, it can be stopped at any height. This means less travel time than with pneumatically operated knives and the result is a higher number of pieces and significantly less wear. Furthermore, a servo drive is more energy efficient and expensive compressed air can be saved.

FASTPACKER
FULLY AUTOMATIC PACKAGING OF TRAYS IN THE SMALLEST SPACE
The FPA FASTPACKER was designed and developed to be able to offer a space-saving, ergonomic, practical and financially lucrative solution in all companies.

On the one hand, the system is easy to operate and technically maintain, and its compact dimensions mean that the system can be installed in small rooms or in the hallway. The dimensions of the system are just (LxWxH) 3100 x 600 x 1650 mm

The system can automatically insert trays of 0.4 to 1 kg of pure type into trays (also with protective corners) and thus offers versatile application options and good investment protection.
Variants with different tray dimensions and tray dimensions are feasible, but affect the external dimensions of the inserter and the size of the investment.

FUNCTIONAL PRINCIPLE
In the tray inlet area, the labels (top and bottom) are checked by cameras. If there are any errors, the tray is then blown out. The trays then move to the receiving position of the lifting and rotating device. Here, the trays are picked up by two suction cups and placed in a nest rotated by 90°. Here, the kinematics pick up the trays and position them in the tray.

The trays are placed above the tray feed, but on the same line. Depending on requirements, they can be rotated by 90° on the conveyor or not. From here, the trays are moved to a magazine, which acts as an intermediate storage area. Short-term gaps in the feed can thus be bridged.

The tray is then brought from the lowest magazine position to the receiving position and loaded. The loaded tray is then brought to the discharge conveyor below the loading position using a lowering aid.

E - BOX PALLETIZER - DEPALLETIZER
SEMI- OR FULLY AUTOMATIC PALLETIZING AND DEPALLETIZING IN THE SMALLEST SPACE

The palletizing system was designed and developed to be able to offer small and medium-sized companies a space-saving, ergonomic, practical and financially lucrative solution.
On the one hand, the system is easy to operate and maintain technically, and its compact dimensions mean that it can be installed in small rooms or in the hallway.

The dimensions of the system are just (LxWxH) 2,250 x 1,100 x 2,500 mm.

The cell can automatically palletize and depalletize E1, E2 and E3 boxes of up to 25 kg, and thus offers a wide range of applications and good investment protection. It is also possible to further automate the system by later connecting conveyor technology or handling modules.

Using this box stacker means that employees are no longer overloaded. The boxes no longer have to be lifted, but only moved horizontally. There is no longer any unergonomic handling of the heavy boxes on the floor or at a height of 1.7 meters.

FUNCTIONAL PRINCIPLE
The boxes are pushed onto the gravity roller conveyor at an ergonomic working height at the input area and the access is automatically and safely closed. The double gripper then moves within the cell to the two boxes that have been placed down, locks them, lifts the boxes over the free area of ​​the pallet and moves them to the free storage space on the pallet.

A stable and maintenance-free drive ensures that the system is highly reliable and easy to clean. The gripper is housed in a protected housing.
The safety door for the input or output of full boxes closes using two-hand operation, the door on the pallet entry side is equipped with two tested safety switches. A light protection grille or an automatic roller door can be optionally selected for an additional charge. However, it should be noted that the length of the system is extended by approx. 800mm due to the safety requirements.

ROBOT SYSTEM for self-service packaging of trays

The first robot solution was developed from the FPA for the final packaging of finished, filled trays.

It was delivered and put into operation just one year after the FPA was founded.

The packaging system takes the fully labeled trays and checks the labels for the correctness of the information. A 6-axis robot then picks up the trays and places them in the corresponding empty cardboard boxes according to the specified packing pattern.

The filled box is then fed into an existing elevator as a stacking unit of 4. The system was designed for high flexibility and is able to process different sizes of cardboard boxes and trays in a pure manner.

After the design and production phase, the system was delivered and put into operation at the beginning of April 2022. As is often the case with new developments, some of the process and reliability of the gripper system had to be optimized until everything worked smoothly.

The system contains two camera systems at the inlet of the cell to monitor and check the printing and position of the labels. Among other things, the correct placement and the order number, including the consistency of the label lettering, are checked.

The system achieves an output of 60 packs per minute. A packaging solution for fresh meat trays with an output of > 80 packs per minute is currently being developed on a similar basis, and will be implemented at a maximum width of 600 mm.

LOOPCUT - for the automatic packaging of fine salamis

This system was implemented in July 2021 by he FPA for the automatic separation and packaging of fine salami from the smoke cart into the flow pack system. The system was delivered and put into operation in April 2022.

The LoopCut was designed to automatically cut off sausage products that are hanging on a smoke skewer for drying and ripening and to automatically package them in the flow pack system.

The operator of the packaging machine uses a lifting aid to lift the smoke sticks with the product chains out of the smoke cart and hangs them in the empty buffer section. Up to 24 smoke skewers are temporarily stored in this buffer.

Optionally, the smoke sticks can also be automatically removed from the smoke cart using a 6-axis robot and hung in the buffer section.

The kinematics of the LoopCut picks up a full smoke skewer and feeds the products into a separating device. A light barrier checks the correct position of the products and the product centering fixes the salamis in place. A knife is then moved between the plastic strips in this clamping device using a toothed belt and cuts the products off the smoke stick.

A conveyor belt takes the products lying parallel on the belt to the packaging machine.
Once there, a funnel above the conveyor chain of the flow wrapping system takes over the individual salamis, registers a free area between the carriers and lets one product after the other fall into the feeder of the flow wrapping system.

The system can be used universally. If there is a major deviation in caliber or if the product length changes, small mechanical adjustments must be made to the LoopCut.
The performance of the system depends on the length and caliber of the products or the number of products on the smoke sticks. This means that a maximum of 80 products per minute can be packaged automatically.

PORTCUT 80 - CUTTING SAUSAGE PRODUCTS

The FPA PortCut 80 for self-service products cuts raw, boiled and cooked sausages. The system cuts product sizes from 35 up to 80 mm caliber with a length of 180 - 400 mm.

The cutting angle of the cutter can be manually adjusted continuously from 45 - 90 degrees. A simple plug-in system allows the knife to be changed in just a few seconds. The very narrow surface of the blade leaves a much lower number of CFU (colony forming units) on the cutting surface compared to cutting with a conventional knife or a circular knife.

FUNCTIONAL PRINCIPLE

The cutting process with the PortCut 80 takes place vertically using a servo drive. The products are held in position by hold-down devices mounted above the transport line.

The exact center of the product is determined with a 2D camera system when it enters the knife area and positioned directly in line with the knife. Thanks to the electrically operated knife, it can be stopped at any height. This means less travel time than with pneumatically operated knives and the result is a higher number of pieces and significantly less wear. Furthermore, a servo drive is more energy efficient and expensive compressed air can be saved.