Yes, it is absolutely possible to successfully automate a line that handles a wide variety of packaging formats — but there is no single robot that can solve every situation on its own.
The right choice depends on:
- available space
- product fragility
- geometry and weight
- frequency and complexity of format changeovers
When these criteria are defined correctly, the robot not only maintains throughput, but also:
- reduces handling errors
- simplifies presentation changes
- increases end‑of‑line stability
The real challenge is not the number of formats, but how they change
In food, beverage, cosmetics, and consumer goods industries, it is common to handle:
- bottles
- trays
- cartons
- shrink packs
- cases of different sizes
At first glance, this may seem like a payload or reach problem.
In reality, the biggest challenge is often format transition.
If the robot requires long adjustments every time the packaging format changes, the line loses effective speed and the expected return disappears during changeover windows.
Before comparing brands or models, it is essential to analyze:
- how products arrive at the robot
- their orientation
- how many format changes occur per shift
- how delicate the handling needs to be
Handling a rigid, uniform pack is very different from manipulating a flexible, unstable, or premium‑finish package.
This difference determines:
- the type of gripper
- the need for vision
- the overall cell architecture
Key criteria for choosing the right robot
1. Payload, reach, and real operating speed
Choosing a robot based only on nominal speed is a common mistake in multi‑format lines.
What really matters is:
- speed with the actual end‑of‑arm tool
- safe acceleration values
- trajectories that do not deform the product
Repeatability is equally critical, as small grip variations can cause downstream jams or poorly formed pallets at the end of the process.
2. Gripper versatility
In many cases, the gripper matters more than the robot itself.
Depending on the application, this may include:
- adjustable mechanical grippers
- vacuum systems
- interchangeable fingers
- hybrid gripping solutions
The smarter the end‑effector, the fewer manual adjustments operators need to perform.
And the simpler the maintenance, the easier it is to scale the solution across multiple lines or shifts.
Which configurations usually deliver the best results
- Delta or SCARA robots work well for high‑speed picking of lightweight products
- 4‑ or 6‑axis articulated robots offer greater flexibility for longer reach, stacking, and full‑case handling
- End‑of‑line palletizing solutions often benefit from compact cells with:
- preconfigured patterns
- guided format changes via HMI
A best practice is to design the cell around the company’s commercial roadmap, not just the current format.
If marketing introduces new sizes frequently, automation must absorb that evolution without costly redesigns.
In this context, it is natural to guide the reader toward URT palletizing cells, especially when grouping, transfer, and variable end‑of‑line formats are involved.
How to avoid unnecessary costs and ensure a profitable project
The most common mistake is over‑engineering:
- oversized robots
- overly complex grippers
- unnecessary vision systems
These choices increase cost and make daily adjustments more difficult.
The goal is not the most sophisticated cell, but the most stable one for the real product mix.
Helpful tools include:
- testing with real packaging samples
- simple matrices linking:
- format
- line speed
- gripping method
- acceptable reject rate
Where ROI really comes from
Return on investment typically comes from:
- fewer stops during format changes
- reduced product damage
- greater consistency when feeding downstream processes
In operations with many SKUs, well‑designed automation does more than save labor — it prevents the silent losses caused by handling errors and operator fatigue.
This argument resonates strongly with production, operations, and supply chain decision‑makers.
FAQ
Can I use the same robot for rigid and flexible packaging?
Yes, but it usually requires a gripper designed to handle both behaviors or a quick tool‑change system. The decision depends on changeover frequency and handling delicacy.
What is more important: the robot or the gripper?
In multi‑format lines, the gripper is often just as critical as the robot. A well‑designed gripping system reduces adjustments, improves stability, and increases the number of formats the cell can handle.
How do I know if my line needs vision?
Vision systems add value when products arrive randomly, with variable positions or difficult orientations. If the flow is stable and well guided, vision may not be necessary.
If you need more info, dont hesitate to call us.