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.

With huge advantages over stationary systems, the transportable 1000 series of robotic palletising solutions, featuring a Fanuc robotic arm, can be easily moved and incorporated into different production lines within a manufacturing facility as and when demand dictates.

With three separate systems under the range, all with upgradeable options, Endoline Robotics’ 1000 series is designed to grow with a company, making it a system for life.

The first in the series, the semi-automatic 1001 system, receives product from a single infeed and palletises on a pallet stationed on the floor. Once the operation is complete, the system signals the operator to remove the full pallet and add a new one to be palletised. While mirroring the process of the 1001, the 1002 palletiser is also semi-automatic, but begins palletising a second pallet when the first is filled, enabling operators to replace the filled pallet with an empty one for continuous operation.

Completing the range is the fully automatic, 1003 system. Products arrive at the palletising position from an infeed conveyor and the robotic arm palletisers according to pre-defined patterns. When the process is complete, the system discharges the loaded pallet onto a conveyor outside the cell.

Each system within the range is designed to handle various pre-defined products with quick changeovers. At speeds of 12 cycles per minute, the Fanuc robotic arm provides precise product handling of carton boxes, display boxes, trays, multipacks, bags and totes.

Ideal for manufacturers who previously rejected palletising automation due to concerns around flexibility, the 1000 series can dramatically increase palletising speed and efficiency, offering an ROI in under 30 months. Industry 4.0 ready, each system can also monitor key performance indicators and manufacturers can extract performance data.

“The launch of the 1000 series of palletising robots strengthens our strategic partnership with Fanuc,” comments Andrew Yates, managing director of Endoline Robotics. “Our customers are increasingly requiring robotic systems; however they also seek flexible solutions which won’t be left redundant if their businesses change. The 1000 series of palletising robots offers a complete solution.”

While flexible and with upgradeable options, the compact nature of the 1000 series makes it ideal for sites with limited space. It can also be easily moved by forklift and quickly installed and commissioned onto different lines as and when demand dictates.

Visit the Endoline Robotics website for more information

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