In a context where labor shortages and strict hygiene demands remain persistent challenges in the food industry, automation has become a key solution. A notable example is the collaboration between Active8 Robots and KUKA, which has revolutionized the sandwich packaging process in the UK through the integration of KR AGILUS HM robots.
The British sandwich industry faces growing consumer demand, with around 11 billion sandwiches consumed annually. However, factors like Brexit and a lack of skilled labor have made it increasingly difficult to maintain efficiency in production lines. Repetitive and monotonous tasks such as sandwich packaging tend to be unappealing to workers, prompting the need for automated solutions.
To address this, Active8 Robots developed an automated system using two KR AGILUS HM robots from KUKA, specifically designed for environments with strict hygiene requirements. These robots can package 50 to 60 sandwiches per minute with high precision and consistency, ensuring product quality.
The process starts with manual sandwich preparation and placement on a conveyor belt. Before being handled by the robots, each sandwich is cut diagonally using ultrasonic technology that guarantees accuracy according to predefined standards. Integrated imaging sensors then verify the quality and integrity of each sandwich, automatically removing those that don’t meet the required specifications. The KR AGILUS HM robots then pick up the approved sandwiches, rotate them 180 degrees, and gently place them into paper bags or boxes for distribution.
To maintain hygiene and ensure delicate handling, the robots are equipped with stainless steel rotary end-of-arm tools that are food-grade compliant. This choice not only meets industry regulations but also enables careful, precise movement during packaging.
The adoption of this automated solution has brought significant benefits, including increased packaging efficiency, improved hygiene through reduced human contact, and lower operational costs thanks to decreased reliance on manual labor. This success story demonstrates how automation can effectively respond to the current challenges facing the food industry and signals a shift toward smarter, more efficient production facilities in the future.
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