Automating product preparation for robotic palletizing: a sanitary and intelligent integration

Situation and challenge

Adapting production to meet a major retailer’s requirements

A leading North American dairy manufacturer needed to adapt its palletizing process to comply with the specific logistics requirements of a large supermarket chain. Pallet compliance, in terms of configuration, stability, and repeatability, required the implementation of a new robotic palletizing cell.

However, this transformation extended beyond palletizing alone.

Upstream, the facility needed to efficiently prepare, orient, validate, and distribute milk bags coming from existing production lines, while meeting the strict constraints of a sanitary environment.

The customer was therefore seeking a solution capable of:

• Integrating with an existing production line
• Managing multiple product flows across a multi-level infrastructure
• Ensuring hygienic, washdown-capable conveying
• Optimally preparing milk bags for robotic handling
• Maintaining operational flexibility, including parallel manual palletizing

To address this challenge, Storcan worked closely with the robotic cell supplier to design and integrate the complete upstream conveying system.

The objective was not simply to transport milk bags, but to design an intelligent and modular flow architecture capable of supporting overall line performance.

Storcan solutions

From engineering to installation, this solution was designed, manufactured, tested, and commissioned by Storcan:

• A sanitary, modular, and intelligent multi-level conveying system: Storcan developed a turnkey solution including engineering, manufacturing, integration, and commissioning of the entire system.

Two superimposed conveyor lines were installed to ensure the initial transfer of milk bags. These conveyors were designed according to sanitary standards enabling thorough washdown and simplified maintenance.

• Dynamic flow management with motorized guides: On the first section of the line, motorized guides were integrated to control product trajectory and allow diversion of milk bags toward a manual palletizing area when required. This approach ensures operational flexibility without complex manual intervention.
• Line merging through an adaptable elevation system: The two superimposed flows are then merged into a single line using a vertically adjustable conveyor with bi-manual adjustment. This mechanism enables dynamic selection of the upper or lower line, optimizing space utilization and maintaining continuous flow.
• Automated quality control through vision: An industrial vision station validates milk bag conformity (shape, positioning).

Non-conforming products are automatically removed via a retractable conveyor, protecting the robotic palletizing process.

• Multi-lane distribution toward the robotic cell: Downstream, a diverter converts the single flow into four distinct lanes, positioning milk bags according to the robotic palletizing cell requirements. This step is critical to ensuring robot throughput and precision.

Results

A high-performing, flexible, and fully integrated line

The deployed solution enabled the customer to:

• Efficiently integrate a robotic cell onto an existing line
• Maintain a conveying system compliant with dairy sanitary standards
• Simultaneously manage multiple product flows with high flexibility
• Automate quality control prior to palletizing
• Optimize product presentation to enhance robot performance
• Preserve a manual palletizing option when required

Beyond transporting milk bags, this project highlights Storcan’s ability to design complex flow architectures, adapt existing lines, and integrate intelligent technologies to achieve customer performance and profitability objectives.

OEM collaboration supporting seamless integration

This project also demonstrated the importance of close collaboration between technology providers. By working jointly with the robotic cell integrator, Storcan ensured optimal synchronization between conveying and robotics, contributing to a smooth and efficient commissioning process.

Conclusion: transforming complexity into operational performance

In modern food manufacturing environments, line performance no longer depends solely on individual equipment, but on the coherence of the entire product flow.

Leveraging 50 years of expertise in automated solutions, Storcan supports manufacturers in transforming operational constraints into drivers of productivity and profitability.

Contact our team to assess your current line configuration.