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 Bosch Rexroth demo in the Action Arena at MachineBuilding.Live showed the integration of a 7-axis Kassow Robot with the VarioFlow Plus conveyor system, complete with vision system.

It highlighted how these systems can be easily combined for various material handling applications, showcasing the flexibility of these components. Visitors were able to see how easy it is to program the robot and to configure the conveyor systems using MTPro.

Visit the Bosch Rexroth website for more information

See all stories for Bosch Rexroth

A unique demo unit how these systems can be easily combined for various material handling applications, and showcases the flexibility of these components. Visitors will be able to see how easy it is to program the robot and to configure the conveyor systems using MTPro.

Visit the Bosch Rexroth website for more information

See all stories for Bosch Rexroth

Discover first-hand how these agile and high-speed robots can revolutionise your manufacturing processes. With impressive payload capacities and precision, Kassow Robots excel in a variety of tasks, from intricate assembly to heavy-duty operations. Their compact design ensures seamless integration into any workspace, maximising efficiency without sacrificing floor space.

Furthermore, its intuitive programming interface simplifies deployment, reducing setup time and costs. The Kassow robot’s advanced safety features ensure reliable operation alongside human workers, enhancing workplace safety.

Visit the Bosch Rexroth website for more information

Highlights include the company’s ctrlX AUTOMATION platform which it says surmounts the classic boundaries between machine control, the IT world and the Internet of Things. The scalable platform enables the flexible design of centralised and decentralised automation topologies.

New products shown at the Hannover Messe include linear robots that can be used for diverse automation requirements such as joining and pressing, handling or dispensing. And you’ll also learn about how Bosch Rexroth is unlocking new possibilities in the field of mobile robotics and service robotics, plus you can discover the full line of 7-axis cobots from Kassow Robots (pictured above).

Another highlight is Bosch Rexroth’s TS2 Booster, which the company says is ten times faster in short-cycle transfer, while still being highly precise in use. Unproductive times before and in the station are significantly reduced.

Visit the Bosch Rexroth website for more information

See all stories for Bosch Rexroth

The white paper aims to provide a solution to common spot welding issues such as shunting, variations of coating and sheet thickness, and weld force disparity. It also addresses the concept that inspection techniques need to be time intensive and unreliable.

Dave Halford, welding industry sector manager at Bosch Rexroth, who authored the report, said: “Adaptive welding remains a small proportion of the UK’s welding market, but its ability to improve the quality of welds and drive costs out of the manufacturing process, cannot be ignored.

“Traditional methods are prone to a variety of weld disturbances, and inspection techniques take up valuable time with mixed results. By taking an adaptive approach manufacturers benefit from real time control and monitoring, as well as improved consistency.”

Weld testing, in particular, is seen as an area where new technology will offer significant improvements, as Halford explained: “Current quality checking methods are problematic and rest on two methods, ultrasonic inspection and manually opening a proportion of completed welds. The first option requires a high level of operator training in order to get consistent results, while the second leads to scrapped parts. Real time monitoring through adaptive welding eradicates the need for these time intensive processes.”

Adapt and change – How adaptive control of resistance welding can cut production costs and improve product quality can be downloaded from https://www.boschrexroth.com/en/gb/trends-and-topics/ls4adaptivewelding

Visit the Bosch Rexroth website for more information.

See all stories for Bosch Rexroth