Capable of handling up to 14 bundles of flour per minute across two production lines, the equivalent of between 56 and 168 individual bags of flour every minute, the new system is already playing a key role in supporting increased production volumes and future growth.

Designed to work alongside an existing Endoline palletiser dedicated to one of the site’s two production lines, the upgrade forms part of a broader automation strategy at the facility. The mill operates two filling lines producing both individual 1-2kg bags and larger 18kg shrink-wrapped bundles. The original system, installed five years ago, manages the individual bags from Line 1. This left Line 2’s individual bags, together with the bundles from both lines, requiring a more flexible palletising solution.

Engineered to accommodate both product formats, the system also incorporates the automatic handling and placement of wax paper interlayer sheets. Bundles are conveyed from both lines at speeds of up to 14 per minute per line, equating to a combined throughput of up to 28 bundles per minute. In addition, individual 1-2kg bags from Line 2 are presented at rates of up to 70 bags per minute.

Driving flexibility to support business growth

The replacement project was driven by the need to overcome limitations within the previous palletising operation, which lacked the flexibility to efficiently handle varying bundle sizes and evolving product formats. As the mill expanded its product range and customer requirements for bundle sizes became more diverse, a more adaptable solution was required to support continued growth.

Combining advanced palletising technology with a fully engineered conveyor network, the system enables both bundled flour products and individual packs to flow seamlessly from packing through to pallet build. By automating what were previously labour-intensive and physically demanding tasks, the flour mill has improved operational efficiency, consistency and working conditions across the site.

Integrated palletising and conveyor system

At the heart of the system is a palletising solution capable of managing product streams from the two filling lines. Bundles and individual packs are transferred via a series of accumulation and transfer conveyors, designed to buffer product flow and maintain a continuous feed into the palletising area without disrupting upstream packing operations.

Operating across the two bundling lines, the palletising system can handle up to 14 bundles per minute per line, delivering high-volume throughput while maintaining precise pallet builds and load stability ready for downstream handling and distribution.

While the palletiser can manage the simultaneous pick-up of bundled products from both lines, it requires a straightforward re-tooling process when switching to palletising individual packs of flour, which are fed down the middle conveyor. This quick-change capability allows the mill to move efficiently between product formats in line with production schedules and changing customer requirements.

To minimise downtime during product changeovers, the tooling transition is carried out automatically via the system HMI. The robot docks its current end-of-arm tool, releases it and automatically connects to the alternative tool, ensuring rapid and controlled transitions between bundle and individual pack handling.

Replacing legacy systems with adaptable automation

“Our customer needed a solution that could replace their existing palletising system with something far more adaptable and capable of supporting long-term growth,” comments Suraj Patel, UK Sales Manager, Endoline Robotics. “By integrating high-speed palletising with a tailored conveyor layout, we’ve delivered a flexible operation that can handle different product formats, varying bundle sizes and increasing volumes.”

While enabling the site to move away from manual-intensive tasks, flexibility has been a central design principle throughout the installation. The modular conveyor layout allows for future expansion and capacity increases, while the palletising system can be easily adapted to accommodate new pack sizes, bundle formats and pallet configurations as the business continues to evolve.

“Modern food manufacturers need automation that delivers both performance and adaptability,” Suraj adds. “This project shows how replacing legacy systems with flexible technology can improve efficiency today while providing the capacity to grow tomorrow.”

Building on a long-term partnership

Although the latest installation represents a major upgrade, it builds on an established partnership between the flour milling business and Endoline. In 2020, Endoline delivered a robotic palletising system at the company’s UK-based mill to support a sharp increase in retail demand during the pandemic, enabling production of more than 167,000 bags of flour per week and improving pallet quality and operational continuity.

That earlier project helped shape the company’s wider automation strategy and demonstrated the long-term benefits of palletising technology within the milling environment. With a long-established milling heritage, the business continues to invest in modern manufacturing solutions to remain competitive in a rapidly changing food production landscape.

The palletising and conveyor upgrade reflects this industry trend, providing the flour mill with a future-proof solution that supports current operations while enabling continued growth.

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

Visit the Robotiq website for more information

See all stories for Robotiq

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.

Visit the Bosch Rexroth website for more information

See all stories for Bosch Rexroth

The TM30S, TM20S and TM6S extend the series’ payload and reach capabilities for applications such as palletising, machine tending and precision handling.

• TM30S: 30 kg payload model designed for heavy-duty collaborative tasks including palletising and machine tending.
• TM20S: 20 kg payload unit offering extended reach for mid-to-high payload operations.
• TM6S: Long-reach 6 kg payload model optimised for precision handling, welding support and mobile robot integration.

Across the S Series, OMRON has introduced upgrades to increase durability and support faster redeployment. All robot arms now feature an IP65 rating for use in washdown or dust-prone environments. Higher-payload units (TM25S, TM30S) incorporate an integrated joint 6 force-torque wrist sensor for improved force-controlled processes. The updated Landmark 2.0 vision-based positioning system is designed to reduce recalibration time when moving robots between stations.

TMflow 2.22 software release

OMRON has also released TMflow 2.22, an update to its no-code programming environment. The new version introduces more granular safety configuration options, expanded remote monitoring and diagnostics and a higher-fidelity simulation engine. Integrated vision tools have been strengthened to support inspection and pick-and-place tasks with greater accuracy.

“By introducing the TM30S, TM20S, and TM6S alongside crucial upgrades like IP65 certification and the integrated joint 6 force torque sensor, we are empowering our customers to automate their most challenging, heavy-duty tasks with greater safety, precision, and flexibility than ever before,” said Qiqi Wang, Global Product Manager at OMRON Robotics and Safety Technologies. “TMflow 2.22 ensures that this immense power remains easy to program and manage, upholding our commitment to harmonious automation.”

Visit the OMRON website for more information

See all stories for OMRON

Palletising is a repetitive and strenuous task that poses risk of injury to workers. For manufacturers looking to increase efficiency, palletising is an easy choice in terms of tasks to automate. Implementing a robotic solution to take the strain of repetitive palletising tasks increases safety for workers and allows staff to be re-allocated to more rewarding, higher-value tasks.

Robotiq offers a choice of two different approaches to easy, simple palletising automation: PAL Ready and PAL Series. PAL Ready is a production-ready palletiser which utilises the UR20 model from Universal Robots. The solution includes everything manufacturers need to get started and is designed for rapid installs. A vacuum gripper, a mobility kit (which allows the cell to be moved to different lines), a safety package and a smart infeed roller conveyor are all included in the PAL Ready package.

PAL Series, on the other hand, is a modular approach based on standard Robotiq components. This option offers a choice of five different palletiser models, along with optional extras such as grippers, safety packages, mobility kits, interlayer racks and more. Users can choose to add or remove these components to suit their application needs.

RARUK Automation is a Robotiq Expert Partner and was named Universal Robots’ Top Global Distributor in 2024. With previous deployments, Robotiq Palletising Solutions have proven popular due to their small footprint, making it easy to fit them into existing production lines. The PE10 has a payload capacity of 11.5 kg (25 lb) and a stacking height of 1,550 mm (60 in). The solution offers a cycle time of 13 cycles/ min.

Designed to enhance efficiency, Robotiq’s easy-to-use software makes it quick and simple to get a robotic palletising solution up and running. Staff can effortlessly adapt production through an intuitive interface. With Robotiq’s Multi-recipe feature, it is easy to accommodate product changeovers.

Visit the RARUK Automation website for more information

See all stories for RARUK Automation

RARUK Automation is the exclusive UK representative for Robotiq, a Canadian manufacturer of end-of-arm tooling and application solutions designed specifically for Universal Robots. Delivering a new approach to simple, fast end-of-line automation, Robotiq has launched PAL Ready and PAL Series which offer two new options for customers.

PAL Ready is a production-ready palletiser, which is fully assembled, tested and ready to run on arrival. The solution includes everything manufacturers need to get started and is designed for rapid installs. PAL Ready offers a palletising solution complete with a vacuum gripper, a mobility kit (which allows the cell to be moved to different lines), a safety package and a smart infeed roller conveyor.

Andrew Mason, Automation Product Manager at RARUK Automation comments: “PAL Ready offers the end user the capacity for flexible redeployment between lines, with its complete hardware and easy-to-use software solution. It is designed exclusively to work with proven, industry-leading Universal Robots.”

On the other hand, PAL Series offers a more modular approach for businesses with custom requirements. This option offers a choice of five different palletiser models, along with optional standard components such as grippers, safety packages, mobility kits, interlayer racks and more. Users can choose to add or remove these components to suit their application needs.

Both of these options are designed to allow businesses to scale with ease, as each solution is based on the same software, building blocks and design logic. For manufacturers looking to determine the right solution for their factory floor, there is even a Palletising Fit Tool which will generate a custom report based on a series of questions about the potential application.

RAR UK says this new step marks a breakthrough in palletising automation, offering shorter timelines, rapid deployment and predictable ROI for businesses. All of this makes palletising automation more accessible to businesses – both large manufacturers and SMEs – and guarantees a safer, more productive facility.

Visit the RARUK Automation website for more information

See all stories for RARUK Automation

On stand D72, RARUK Automation will be demonstrating the PE Series Palletising Solution from Robotiq. The solution was designed specifically for the Universal Robots range of 6-axis cobot arms and there are a variety of options to suit different UR models. For this demonstration, the palletising solution will be paired with the newly upgraded UR12e. With a recently improved payload capacity of 12.5 kg/ 27.5 lbs, this model has a reach of 1300 mm / 51.2 in whilst maintaining a compact footprint.

With many manufacturers struggling with labour shortages, robotic palletising enables workers to be re-allocated to higher value, safer tasks. This eliminates the risk of RSI associated with manual palletising. Robotiq’s full range of palletising solutions are fast to set up, easy to scale and do not require annual software licencing fees.

Material handling with mobile robots

Working in collaboration with the palletising cell on stand D72, the MiR600 from Mobile Industrial Robots will be transporting the pallet once loaded. This showcases how workflows can be completely automated in real-life applications and how different robotic solutions can work together. The MiR600 can move 600 kg payloads autonomously at a speed of 2m/s in demanding environments. The AMR is IP52 rated, with an ability to withstand dust and fluids. Offering enhanced worker safety due to multi-sensor systems and cameras that feed data into an advanced planning algorithm, the MiR600 meets ISO 3691-4 safety standards.

Another mobile robot on RARUK Automation’s stand will be the ER-FLEX, created by Enabled Robotics. The robot combines a MiR250 mobile robot base with a Universal Robots cobot arm mounted on top (there are a range of UR models to choose from). This mobile cobot can be used for transporting and handling materials, saving valuable worker time and improving productivity. The ER-FLEX can be used for 20 hours a day, or around the clock with a smart layout.

AI vision for packing

Completing the range of demonstrations on RARUK Automation’s stand will be an AI vision application, using Cambrian Vision on a UR5e. The vision system works by capturing images with a 3D camera mounted on the robot arm, which are then routed through an AI model and 3D co-ordinates are returned for any pickable parts. The UR robot will then move to pick the part and pack it in a uniform orientation. Cambrian Vision offers prediction times of 0.2 seconds. The vision system can detect difficult part materials such as shiny metals and transparent plastics. The AI technology enables the system to work in a range of challenging artificial and natural lighting conditions.

The PPMA Total Show 2025 promises to highlight the very latest in machinery, robotics, vision systems and automation all under one roof. On stand D72, visitors will have the chance to see innovative collaborative robot technology in action and ask any questions they may have. Whether it is packing, palletising or material handling there are a range of scalable, intelligent solutions available from trusted automation distributor RARUK Automation.

Visit the RARUK Automation website for more information

See all stories for RARUK Automation

By extending the RB portfolio to incorporate FANUC’s CRX 20 and 30 models, both companies are confident that more manufacturers – including SMEs – can now enjoy the efficiency gains, energy wins and cost-saving benefits that automation delivers.

Renowned in the market for being safe, efficient and easy to programme, FANUC’s CRX series of collaborative robots comes with minimal maintenance requirements and extended warranties of up to five years.

Reeco will integrate the 20iA (20kg payload) and 30iA (30kg payload) models into their established RB palletiser range, ensuring their customers can benefit from the superior reliability and enhanced performance that are synonymous with the FANUC brand.

“FANUC are a leading OEM, a reputable brand in the world of automation. Many end-users who have adopted automation are already familiar with their technology and the reliability and robustness of their products,” explains Rosie Davies, Managing Director of Reeco Automation. “Extending our RB offering to incorporate FANUC collaborative robots therefore makes perfect sense and is the next logical step in our development of the range. As a global frontrunner in robotic automation, this partnership will complement our future export strategy; another key factor in our decision.”

Reeco’s RB Palletiser range offers an automated alternative for manual loading tasks, providing unrivalled functionality and safe operation alongside human activity. Capable of more complex executions than other cobot palletisers, each RB system occupies a very small footprint, can be integrated swiftly, and is surprisingly simple to use.

For Oliver Selby, Head of Sales for FANUC UK, the opportunity to align Reeco’s plans for the RB Palletiser with FANUC’s vision for the CRX range comes at just the right time: “FANUC’s system integrator network is already strong, and we place huge value on the relationships we’ve built with those partners across a range of sectors. Recent figures from BARA show that UK food and beverage manufacturing is currently the fastest growing sector in terms of automation adoption.

“With vacancies proving hard to fill, robots offer a clear alternative for applications such as manual loading, enabling businesses to redeploy human employees towards more value-added tasks. By working with Reeco and supporting their RB robot palletising range, we can ensure that more food and beverage companies, including SMEs, are able to reap the benefits of automation.”

The synergies between FANUC and Reeco were apparent from day one, as Rosie explains: “Our technical teams have been working closely together over the past few months to ensure that FANUC’s collaborative robots can be seamlessly integrated into the RB range and the mutual support and respect between our two companies is evident. For our end-users, having a robust, well-built, international-renowned product from FANUC within our proven automated palletising system will only boost confidence in our offering.”

Visit the FANUC website for more information

See all stories for FANUC

Established in 1996 by Nick Cesare, PACE has completed over 250 installations for packers operating in a wide range of sectors, including agriculture, aggregates, chemicals and powders and animal feeds.

As well as developing end-of-line solutions around its four core products – the Gemini twin head weigher, Orion Weigher, Orion Weigher and sack placer, and the CBC sack placer and stitcher line – PACE is also the sole UK and Ireland importer, distributor and service partner to TMI, one of Spain’s leading bagging, palletizing and wrapping machinery manufacturers, and Innova’s Stretch Hood pallet wrapping system.

In addition to its core machinery range and agreements with TMI and Innova, PACE has a long-standing partnership with Motoman of Japan, allowing it to offer a wide range of robots, including pick-and-place and specialist heavy-lifting models.

Most recently, Nick introduced his own range of cobots. The collaborative robots offer low cost-of-ownership and are extremely easy to install and programme. Designed to handle cartons and cardboard boxes up to 20kg in weight and at a speed of up to 15 cartons per minute, the PACE CoBot is available to buy from £78,000, with competitive rental prices also available.

A PPMA member, PACE has attended the PPMA Show since 2011 but has never before exhibited at Automation UK.

“I think it is fair to say that since 1996, we have established ourselves as one of the leading suppliers of automated end-of-line palletizing and packaging solutions across food and drink, agriculture and several other sectors,” says managing director Nick Cesare. “Even as we mark our 30th year in business, we are still ambitious and know that there are many other industry sectors looking to automate their packing and end-of-line operations as they seek greater efficiencies and operate more effectively when faced with significant labour shortages.

“Automation UK aims to be the national automation and robotics show and wants to showcase the latest automation and robotics solutions available is a wide range of stakeholders. That’s why we will be there and hopefully we will meet people from different manufacturing sectors who might not be aware of us and what we can do to help them.”

With the new ELEVATE lifting column from LINAK, the company has extended the working reach of cobot palletisers, allowing you to palletise higher. It simultaneously delivers the speed, precision and flexibility required to optimise your palletising processes. Easy setup, programming and system monitoring help you boost performance across a wide range of cobot brands and models.

Join LINAK on stand 31 at Machine Building North to find out more about ELEVATE.