This recognition marks the fourth major industry award for the PINovAlign system, underscoring its impact on high-speed, high-precision photonics alignment. The platform combines advanced motion control, integrated alignment algorithms, and high-performance hardware to significantly improve throughput and repeatability in photonic device manufacturing and testing.

Designed for silicon photonics wafer testing, high-throughput fibre alignment, FAU (fibre array unit) alignment, and PIC (photonic integrated circuit) alignment in both test and assembly environments, PINovAlign’s parallel, multi-channel optimisation approach addresses one of the key bottlenecks in scaling silicon photonics manufacturing. By combining high-dynamics precision motion with embedded alignment intelligence, the system enables rapid, repeatable coupling of optical components with nanometre-level accuracy.

At the core of the platform, the PILightning algorithm dramatically accelerates first-light acquisition and alignment convergence compared to legacy, sequential methods. This results in significantly shorter cycle times, higher yield, and improved process stability – critical factors for volume production.

As silicon photonics continues to emerge as a foundational technology for AI infrastructure and next-generation data centres, the need for fast, automated, and scalable alignment solutions becomes essential. By reducing alignment time from minutes to seconds and enabling parallel, multi-channel optimisation, PINovAlign helps remove a major barrier to mass adoption, supporting the growth of an industry that will underpin future high-speed data communication.

By replacing electrons with photons, photonic computer chips have the potential to save huge amounts of energy in next generation data centres.

A long-standing automation partnership between a Swiss machine builder and one of the world’s leading manufacturers of industrial robots is aiming to help transform the pharmaceutical supply chain in Europe with the launch of what is believed to be the ‘smallest’ automated palletising cell for vials and pre-filled syringes.

Swiss-based Robotronic has partnered with Mitsubishi Electric’s Factory Automation EMEA division for more than two decades. Now, the two organisations are collaborating together on a new low-footprint cell to help the pharmaceutical industry overcome record-high shortages across Europe in recent years for medicines ranging from children’s cough syrups through to antibiotics and even cancer treatments.

The growing demand, which has impacted patient treatment and quality of life, has led the European Medicines Agency to increasingly focus on one of the main causes of shortages – manufacturing and quality issues – with the aim of ultimately strengthening the fragile pharmaceutical supply chain.

Mike Weber, founder of Robotronic, says faster production is required to shorten lead times and cope with the ever-increasing demand. “We are a Swiss company concentrating on machine building with robotic applications for the pharmaceutical industry, including everything from de-nesting and re-nesting, through to de-traying, re-traying, and palletising. We have specific expertise in vial and pre-filled syringe handling, offering solutions that deliver maximum efficiency with a small footprint, and enabling pharmaceutical manufacturers to rise to the challenges in their supply chain.”

One of the key challenges for Robotronics is compliance. “Pharmaceutical consistency is about more than quality,” says Mike. “It is also about regulatory compliance and safety.

“To get the required productivity, we need two robots working very closely together at high-speed, but we also need the assurance that the delicate products being handled will not be damaged in the process.”

The Robotronic choice is Mitsubishi Electric, specifically the FR series, a highly flexible robot with compact arm sizes that is equipped with SoftTouch technology.

The result is a small footprint automation solution with increased productivity for handling pallets as small as 120cm x 80cm. Most importantly, the FR series has built-in compliance control that offers soft touch capability that delivers zero product damage with no glass-to-glass contact, no broken glass and is easy-to-clean.

“The challenge was to have two robots operating side by side in a confined environment without compromising speed or precision,” says Mike. “With Mitsubishi Electric’s help, we have two robots driving at full speed within millimetres of each other with no possibility of collision. This enables our cells to process up to 600 products a minute, without really challenging the robots.”

He concludes: “The relationship between Robotronic and Mitsubishi Electric is a true technological partnership – a combination of deep pharmaceutical process expertise allied to best-in-class robotic technology. Together, we believe we can develop machines that can shorten lead times and create a more robust pharmaceutical supply chain.”

Stefan Knauf, Division Manager at Mitsubishi Electric Factory Automation – German Branch, adds: “The biggest challenge was enabling Robotronic to safely and continuously operate two robots side-by-side in a confined environment, without compromising speed or precision. Our FR series robots with additional servo axis perfectly matched their requirements to deliver high throughput from a small footprint.

“The unique, built-in compliance control also allows the robots to gently handle glass vials without the risk of damage. Ultimately, in pharmaceutical production, consistency isn’t just about quality, it is about regulatory compliance and safety. Our relationship with Robotronic is a true technological partnership. Mike and his team bring deep pharmaceutical process expertise and we bring robotics innovation.”

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Like many other industries, the woodworking sector faces a variety of challenges. These include quality assurance, untapped efficiency potential, and a shortage of skilled workers. One possible response is further automation. Automation can reduce errors, improve quality, and increase efficiency. In addition, production can be increased and accelerated because machines can operate 24/7 and perform quality control faster and more precisely than humans. Finally, the increasingly scarce human resources can be deployed more purposefully by automating monotonous and physically demanding tasks.

HOMAG Bohrsysteme has developed an automated solution that addresses these challenges. The company is part of the HOMAG Group and provides customers in the woodworking industry with a wide range of support options through its high-tech machines and systems. Its product portfolio includes CNC machining centres, through-feed drilling machines, drilling and dowel-insertion machines, as well as machines for drilling and fitting insertion technology.

The newly developed solution focuses on fully automated loading of a vertical CNC machining centre. At the literal centre of the system is a robot that picks wooden workpieces from a stack, feeds them into the CNC machine, and removes and places them after processing. The key feature is that the workpieces are all individual and their shape and size are not known in advance. In addition, they are arranged chaotically on the stack. Furthermore, not only are the workpieces different from one another, but each must also be drilled individually. The relevant information is stored in a barcode on the workpiece.

Machine vision enables processing to take place completely autonomously despite these challenges. With the help of the machine vision software MVTec HALCON, the robot can recognise the different workpieces and grasp them safely. The software executes numerous algorithms and also reads the barcode information on the workpieces, forwarding it to the CNC machine. Based on this information, the required, different drilling operations are carried out.

Fully automating a labour-intensive process step

Such a fully automated cell developed by HOMAG is in operation at the carpentry workshop of MAB Möbel AG. The company from Muotathal, Switzerland, has been producing quality furniture since 1951 based on ecological and design-oriented principles.

“We want to continue developing with solutions that truly make sense. The further development of the cell with laser scanning and chaotic stacking was the function we had been waiting for. This allows the cell to meet our goal of batch size 1 production – and only then does automation make sense for us,” explains Luca Zingg, member of the management board responsible for corporate development at MAB.

Until now, an employee handled the loading of the CNC machining centre. This involved picking up the workpieces, scanning the attached barcode, placing them into the CNC machine, and depositing them on another pallet after processing. After several hours, this monotonous task becomes physically demanding and is not particularly efficient in terms of profitability.

Tobias Schwarz, Senior Director Product Development at HOMAG Bohrsysteme, explains the goal of the automation: “MAB has set itself the objective of increasing productivity, deploying employees more effectively – and above all in less physically demanding workplaces – and thereby reducing costs.

Another advantage of a fully automated production process is that the workpieces no longer need to be sorted before processing, since the application can also handle chaotically arranged stacks. This saves time in the upstream process step, which further increases productivity.”

The challenge during implementation was to develop a completely new solution, as nothing like this previously existed on the market. The task is also not easy for the machine vision system. This is due, firstly, to the enormous variety of workpieces – different surface decors must also be processed. Secondly, the image processing must function under ambient light. Because not every area is fully illuminated, less powerful vision systems may have difficulty determining the exact position of the workpieces. Finally, it is technically demanding to separate the surfaces of relatively flat boards.

“Despite these challenges, it was clear that such a fully automated solution had to be based on machine vision. We had to teach the robot to see. With other technologies, such as sensors, practical implementation would be virtually impossible – particularly in terms of speed,” explains Schwarz.

Enabling the robot to recognise individual workpieces

The application consists of several hardware components. At its core is a six-axis robot. A vacuum surface gripper system is used as an end effector. A 3D laser scanner is also mounted on the robot’s gripper arm. The drilling operations take place in the DRILLTEQ V-310 CNC machining centre from HOMAG. The machining centre offers a wide range of options for precise processing of wooden workpieces.

For the machine vision software, HOMAG chose MVTec HALCON. “We have been working with MVTec’s software for some time. HALCON has a huge pool of machine vision operators that allow virtually all machine vision applications to be implemented robustly. In addition, the software is flexible when it comes to combining different hardware components. And if technical questions arise, you can simply contact MVTec’s customer service,” explains Schwarz regarding the decision.

At MAB, the production process proceeds as follows: An employee places wooden workpieces onto an unknown and chaotic stack in the work area. The robot then moves over the stack so that the 3D laser scanner can scan it from above. The laser scanner then creates a 3D point cloud – a highly precise three-dimensional representation of objects consisting of numerous individual data points.

After image acquisition, the machine vision software MVTec HALCON extracts the top layer of wooden workpieces from the 3D point cloud and determines the spatial position of each individual workpiece. A stacking algorithm then calculates the optimal order in which the robot should remove the workpieces. This is an important detail because an unevenly unloaded stack could collapse. The robot then begins its work, removing the wooden workpieces according to the calculated order and transferring them to the CNC machining center. Before this, the 3D laser scanner captures a 2D image of the code. MVTec HALCON reads the code and transmits the information to the machine.

The workpiece is then processed according to this information. Afterward, the robot picks up the workpiece again and places it on the target stack.

Multiple image processing tasks

“We are seeing machine vision becoming increasingly popular in the woodworking industry and among carpentry workshops. Our software, MVTec HALCON, offers numerous methods – for example for inspection tasks or for collaboration with robots – that can sustainably support automation and digitalisation in this sector,” says Jan Gärtner, Product Manager HALCON at MVTec.

For the robot in the MAB system to work autonomously and grasp the workpieces precisely, the machine vision software must perform several tasks. First, MVTec HALCON converts the 3D point cloud into information for further processing. For this purpose, HALCON uses 3D object models. This central container forms the starting point for creating a coordinate system within the machine vision software, which is then transmitted to the robot.

Various HALCON operators first determine the distance from the gripper to the pallet, then calculate the top layer of workpieces, and finally determine the precise position of each individual workpiece. These positions are integrated into the coordinate system of the HALCON machine vision software and transferred to the robot.

During the 3D scanner’s capture of the top layer of the pallet, it also records 2D images. HALCON uses these images to read the information from the barcode attached to each workpiece. The challenge here is that the captured image is quite large, while the barcode region is correspondingly small. Reading such small barcodes is a major challenge for any industrial image processing software.

“The image-processing part of the implementation was not entirely trivial. Because of the flat boards, we had to combine 2D and 3D methods. This was possible with HALCON and significantly simplified the implementation,” explains Schwarz.

The system went into operation at MAB Möbel AG in summer 2025. “Thanks to the close coordination with the partners involved, we were able to achieve very good results right from commissioning. The system is now operating very reliably, which makes us very satisfied and gives us confidence for the future,” explains Luca Zingg.

“The increased level of automation significantly relieves MAB, as the employees who previously carried out this task can now focus on other, more important activities. At the same time, this solution represents an important development for us, because it allows us to significantly increase the automation level of our core machines and thus offer customers additional added value,” adds Tobias Schwarz, continuing: “Machine vision plays an important role here, because the technology acts as an automation enabler. In our collaboration with MVTec, we see the opportunity to offer our customers first-class and reliable solutions.”

While early cryogenic motion solutions relied on stacked XYZ stages, emerging applications now require 5- and 6-degree-of-freedom alignment systems capable of handling larger payloads and more complex optical configurations.

PI’s concept approach centres on compact, 6DOF parallel-kinematics, designed to deliver nanometre-scale precision across multiple axes within the confined environments of cryostats and dilution refrigerators. Engineered to support key optical tasks – including beam steering, lens aberration correction, polarization control, fibre alignment, and precision positioning of dispersive elements such as gratings and prisms – these systems operate at ultra-low temperatures down below 4K, while enabling motion of several hundred grams over millimetre-scale travel ranges, all with high stability and repeatability.

Hexapod-type parallel kinematics enable simultaneous control of all six degrees of freedom, reducing error accumulation common in stacked systems. Additional advantages include low inertia, requiring less energy, a programmable pivot point for precise rotational alignment, and an open aperture for unobstructed optical access.

The piezo-based architecture minimises heat generation and enables self-locking operation even when power is switched off, an advantage for thermally sensitive low-temperature environments. Non-magnetic materials and UHV compatibility further support integration near sensitive quantum devices.

With this initiative, PI is positioning its motion technologies to support the next generation of quantum research and advanced cryogenic photonic systems.

Combining robust design, food-safe materials and adaptive silicone fingers, the HPSX directly addresses long-standing automation challenges where rapid, precise and gentle product handling is essential.

“In developing the HPSX, we refined the gripper’s shape, dimensions and internal geometry to maximise gripping force while minimising air volume,” says Peter Potters, Product Manager at Festo. “This enables faster cycle times and multiple picks per second. At the same time, we selected a silicone material that is soft enough to prevent product damage but firm enough to securely grip objects and withstand high acceleration.”

The new gripper’s design reduces air consumption while maintaining high gripping force, enabling quicker actuation and faster picking cycles. The HPSX has been designed and tested to withstand acceleration forces of up to 15G while handling loads of up to 0.5 kg, ensuring reliable performance even in high-speed applications. This combination of low air volume, strong grip and acceleration resistance delivers both speed and consistency on fast-moving production lines.

Gripper fingers are manufactured from a soft, silicone-based material specifically chosen for its controlled flexibility. This allows the HPSX to conform to delicate, irregularly shaped or hygienically sensitive products without damaging them. The adaptive design eliminates the need for rigid, application-specific tooling, making the HPSX ideal for handling fragile food items, pharmaceutical products and cosmetics.

To meet stringent hygiene requirements, the HPSX features a corrosion-resistant, sanitary design that is easy to clean and maintain. The gripper has an IP69k high-pressure washdown rating and is built to withstand aggressive cleaning processes common in food and pharmaceutical environments. It complies with EC 1935/2004 requirements and uses FDA-compliant, food-grade and metal-detectable materials, ensuring safe operation in regulated production environments.

The HPSX can handle a wide range of product shapes and sizes without requiring a tool change, significantly reducing mechanical changeover time. This flexibility is particularly valuable in applications such as cosmetics kitting, where a single gripper may need to pick and place multiple product types within the same production run. By eliminating the need for frequent gripper swaps, manufacturers benefit from reduced downtime and increased overall equipment effectiveness.

Available in three sizes (40 mm, 70 mm and 100 mm) and in two-, three- and four-finger configurations, the HPSX offers nine variants to suit diverse applications. A universal ISO50 fitting enables straightforward attachment to existing robotic end-of-arm tooling.

In addition, the HPSX integrates seamlessly with Festo’s broader automation portfolio, including controllers, valves and pneumatic systems. Using single source reduces installation and programming complexity by eliminating interface and compatibility issues between components from different suppliers. For OEMs and end users, this translates into faster commissioning, simplified troubleshooting and a single point of contact for service and support – further increasing uptime.

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The automation programme began in 2018, when Hanover introduced its first collaborative robot to improve the accuracy and efficiency of testing electronic boards used in its LED passenger display systems. Working with automation integrator Absolute Robotics, Hanover deployed Techman collaborative robots to automate the repetitive and highly precise testing process.

Since then, the system has expanded significantly. Today, 11 Techman robots are installed at Hanover’s Lewes manufacturing facility, including TM5-900 and TM12 models, supporting continuous inspection and testing operations across multiple lines.

Automating quality control

Hanover Displays manufactures passenger information and LED destination displays used by transport operators worldwide. As the company brought PCB production back in-house, it needed a reliable way to test and inspect thousands of circuit boards each year. Previously, this process required manual handling and constant operator attention.

The introduction of collaborative robots transformed the testing workflow. Equipped with integrated vision systems, the robots load boards, operate test equipment, verify LED sequences and record the results of each test. This automation enables consistent cycle times and supports unmanned operation, including overnight production runs. The introduction of the cobots has gained significant data and insights to help improve their first-time pass rate from 94% to 99.5%, strengthened department collaboration, and enhanced how Hanover design and test new products.

Proven reliability over eight years

One of the most significant findings of Hanover’s cobot deployment has been the proven reliability of the Techman robots in daily production.

Reece Mills, Sales and Operations Control Manager at Hanover Displays, commented: “Since installing the first Techman robot in 2018, the reliability has been exceptional. In eight years of operation across our cobots, we have only experienced a single joint failure. That level of performance really demonstrates the quality and robustness of the TM robots.”

The collaborative robots have allowed Hanover to maintain extremely high testing accuracy while freeing skilled employees from repetitive tasks and enabling them to focus on higher-value production activities.

Partnership driving automation success

The automated testing solution was delivered by Absolute Robotics, an automation specialist and integration partner for LG Motion. Together, the companies developed a flexible system capable of handling the wide variety of board sizes and configurations produced by Hanover.

By combining collaborative robotics with custom tooling and automated test equipment, Hanover achieved significant gains in productivity and quality assurance, including improved traceability and the ability to run automated tests around the clock.

Reaching one million automated PCB board tests represents a major milestone for Hanover Displays and highlights the long-term value of collaborative robot automation in electronics manufacturing.

The project demonstrates how advanced robotics can deliver consistent quality, improved efficiency and long-term reliability in demanding industrial environments.

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Across Europe and North America, beverage producers, from kombucha and bottled water to major soft drink brands, are standardising cobot palletising to reduce labour strain, control costs, and modernise production.

If palletising is still one of the most manual steps in your production line, you’ll want to hear what triggered the automation decision at Martin Ray Winery, how the installation went, and what the first months of operation looked like.

Register to attend the webinar here

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The food industry is experiencing a transformative shift in quality control, due in part to advances in artificial intelligence (AI). When combined with rule-based machine vision, AI is enabling automation of processes that were previously impossible, unlocking new levels of productivity and quality assurance.

Cheese consumption is booming globally, and producers are facing increasing challenges as they scale production. Labour shortages, particularly in Europe, are pushing dairies to adopt automation to increase efficiency. Meanwhile, sustainability is becoming a central concern, with an increased focus on reducing waste and conserving resources. Additionally, consumers are demanding higher-quality products with more variety, further intensifying pressure on producers.

As Eberle’s Machine Vision Engineer, Dorian Kopfle, explains: “The cheese-ripening process, which can last up to 14 months, requires constant monitoring to avoid mold and ensure quality. Manually inspecting thousands of cheese wheels is virtually impossible, which is why Gebr. Baldauf, a traditional dairy, turned to us for an automated solution.”

Automation with machine vision and AI

Gebr. Baldauf, located in the Allgau region, commissioned Eberle to solve these challenges. The result is a fully automated monitoring system, that combines a mobile care robot, cameras, and onboard image processing.

The process begins with the inspection of cheese wheels for defects, such as mold spots or blemishes. A 4K camera captures high-resolution images, which are analysed using advanced machine-vision algorithms from MVTec HALCON. The software uses deep-learning methods to detect anomalies earlier, minimising process deviations and waste. The data is stored and made available via a web interface, enabling remote monitoring and control. Simultaneously, the mobile care robot performs its task of treating the cheese wheels, ensuring proper rind formation and removal of unwanted smear layers.

This system not only increases efficiency by reducing manual inspection but also improves the consistency and quality of the final product.

Key outcomes and business impact

The deployment of this automated system has provided several key benefits for Gebr. Baldauf, including:

• Increased efficiency: The mobile care robot operates autonomously, reducing manual labour while ensuring that each cheese wheel is inspected and treated thoroughly.
• Waste reduction: Early detection of mold or defects allows for timely intervention, preventing rejected cheese and minimising waste.
• Improved quality control: The system ensures more consistent and less subjective inspection results by replacing manual methods with AI. As a result, the process achieves a 100% inspection rate, applying the same inspection criteria throughout.
• Full traceability: The integration of industrial image processing ensures complete product traceability. All inspection results are stored digitally for easy access, enabling better decision-making and long-term process optimisation.

Overcoming technical challenges with AI

A significant challenge in developing this system was the natural variability of cheese. Every wheel looks different and undergoes significant changes during the ripening process, which makes rule-based machine vision methods less effective. To overcome this, Eberle utilized AI and deep learning to create a system that could adapt to the unique characteristics of each cheese wheel.

The MVTec HALCON software was instrumental in this process. By training a deep-learning network with a large dataset of cheese images, the system is able to reliably detect defects such as cracks, mold, and discoloration, while ignoring the natural variations inherent to the process. This technology ensures that even subtle anomalies are spotted, allowing for earlier intervention and better quality control.

Eberle’s goal was not only to automate the inspection process, but to fully integrate AI into the cheese-ripening workflow. Currently, the system is capable of performing real-time inspections and autonomous care, with minimal human involvement. However, the company is working on refining the system further to handle all types of cheese and stages of ripening, with the long-term goal of creating a fully automated, AI-driven system that requires no human input.

The system also provides a solid foundation for future digitalisation efforts, with the potential for integration into larger digital platforms, such as ERP systems and the cloud, to further optimise the production process.

Scaling and further digitalisation

Building on the success of this project, Eberle is now focused on scaling the solution to meet the needs of the entire cheese industry. The company plans to standardise the system and integrate it into both mobile and stationary care robots for cheese production worldwide.

Furthermore, the system’s AI capabilities are continually evolving. Eberle aims to refine the deep-learning models to handle different cheese types and ripening stages, enabling fully automated classification and inspection. This will allow producers to further reduce human involvement while maintaining the highest standards of quality.

As Christoph Muxel of Eberle summarises, “Our machine vision-based solution demonstrates how automation can sustainably improve quality, efficiency, and competitiveness in the food industry. This project is just the beginning, and we’re excited to take these innovations to a global scale.”

Engineered for manufacturers seeking to quickly deploy an automated solution for medium- and high-volume applications, the ROBBI 360 cobot provides flexibility and user-friendly programming for quick setup and easy adjustments.

The ROBBI 360 manual load/unload turntable features a maximum payload of 150kg per side enabling users to boost productivity by up to 60% compared to cobots with a single loading station. A cobot with a turntable can easily enable an arc-on of 50 to 80%, or a 4X to 8X improvement compared to manual welding.

ROBBI 360 is delivered as a complete “plug and play” package that has been weld-tested before shipping. With the addition of power, shop air, filler metal and shielding gas, it is ready to weld. ROBBI 360 includes a Universal Robots’ UR10e cobot, a 3469 x 2228 x 2628mm cell enclosure for protection, turntable with a 1200 x 800mm work envelope, an ESAB Aristo 500ix or Aristo Edge 500R power source and matching feeder, an integrated fume extraction hood and all electrical and gas connections. The entire assembly is mounted on a skid with fork truck pockets for easy positioning and redeployment. The fully-enclosed workstation has rigid aluminium cell walls and a rugged steel base that ensures no vibration and a stable TCP (tool centre point) that prevents having to make adjustments after moving.

“With its simplicity of ordering, deployment and operation – plus our safety and health features – ROBBI 360 overcomes traditional barriers to welding automation,” says Tom van Dooren, Global Product Manager, Integrated Robotic Systems and Mechanised Solutions, ESAB.

“The ESAB Teach Tool uses a ‘no code’ or plain language program so users can effortlessly incorporate a multitude of functions that enhance performance and productivity. There is no need for a robot programmer on staff, which is often the case with small- to medium-sized operations. I like to say, ‘If you can count to three, you can program me.’ Users can easily program each side of the turntable to weld different parts!”

Safe and sturdy

ROBBI 360 provides a controlled welding environment with UV and infrared protection, integrated fume extraction hoods, noise reduction and dust and debris trays. Walls contain dark green inactinic polycarbonate DIN 5 see-through glass to protect against light from the welding arc. Pressure sensors are located throughout the Cobot arm for crash protection. Safety interlocks ensure the Cobot will not operate if the table is not correctly locked or if the doors are open. As an option, users can add ESAB’s WeldQAS automatic weld monitoring system.

Power source options

The Aristo Edge 500R power source and RoboFeed Edge robotic wire feeder offer next-generation process control and wire feeding capabilities. Aristo Edge 500R ensures precise arc starts and enhanced stability across four advanced WeldModes – THIN, ROOT, ROOT Pipe and SPEED – as well as an Advanced Pulse WeldMode. All WeldModes enhance arc stability, offer more control at faster travel speeds and reduce spatter for less post-weld clean-up. The Aristo Edge platform also empowers independent development of synergic lines and process updates.

The Aristo 500ix, paired with the RobustFeed wire feeder, delivers proven reliability in the toughest industrial conditions and features pre-programmed synergic lines for MIG and pulsed MIG applications using most welding alloys.

In the food industry, solutions are in demand that increase efficiency, meet strict hygiene and safety requirements, and enable gentle product transport. Therefore, manufacturers are increasingly investing in modern automation that fulfils these complex requirements.

One solution is the VarioFlow plus – a chain conveyor system from Bosch Rexroth, which, in combination with pre-existing automation and integration from Hitmark Robotics, enables excellent results in palletising, depalletising, and order-picking processes.

The challenges of the food industry – such as variable batch sizes, diverse packaging solutions, and the need for rapid changeovers – require sophisticated solutions for pick-and-place automation. Consequently, more and more companies are opting for comprehensive robotic lines that not only accelerate processes but also ensure their reproducibility and consistently high quality.

This type of implementation is offered by Hitmark Robotics – an integrator of industrial solutions specialising in the automation of end-of-line packaging. The company designs and implements palletising robots, picking stations, depalletising systems and complete transport and control systems. A recent example of this is a production line realised in collaboration with Bosch Rexroth.

Safe transport of demanding products

In the implementation for a dairy producer, the main challenge was to ensure the safe and smooth transport of cartons and crates without damaging them. The VarioFlow plus chain conveyor system, with a system width of 320 mm and a smooth chain surface, is used – ideal for sensitive goods that must be handled with care.

The Rexroth solution consists of: 10 VarioFlow plus chain conveyors with a total length of approximately 57 metres; 10 gear motors; 10 active transfer bridges; and aluminium profile rails with a slide rail for gentle product transport with a wide guide surface.

The cardboard boxes are delivered directly to the line from the packaging machines, lifted vertically, and transported at a height of approximately 2.5 metres. This system layout allows for continuous production while simultaneously leaving free space underneath the system, which is used for both employee traffic and for operating transport carts.

Robot palletising – precision that pays off

At the end of the line, there are stations that prepare packages for collection by the palletising robot. Here, the system automatically separates the products and arranges them according to a defined pattern. Thanks to the integration with the automation system developed by Hitmark, it is not only possible to smoothly connect the line to the robot but also to continuously monitor operating parameters and quickly reconfigure in case of packaging or format changes.

Bosch Rexroth supplied a highly developed transport system; Hitmark Robotics handled its integration, automation configuration and connection to the palletising system. Both companies share a common vision: to create solutions that function reliably, flexibly and scalably, even in the most demanding industries. Key benefits of the implementation included:

• Minimised risk of damage to transported goods
• Optimal use of space
• Consistent performance
• Ability for rapid expansion or reconfiguration
• Automatic preparation of packages for palletising
• Reliable operation even under difficult production conditions

The future of automation

Modern automation must be forward-thinking, consider the actual needs of the facility, allow for flexibility, and at the same time enable safe processes.

The combination of Hitmark Robotics’ expertise and Bosch Rexroth’s reliable products, such as the VarioFlow plus chain conveyor system, provides an optimal solution. And if palletising, mixing, or transporting food and its packaging becomes a bottleneck in your company, it is worth exploring which solution is right for you.

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