Packing & Palletizing

Product packed & palletized consistently increasing quality & throughput

Packing and
Palletizing Solutions
 Contents
3 | Note from Motion Controls Robotics

4 | Packing and Palletizing Overview

5 | FANUC Robots

7 | Packing and Palletizing - 1 robots

8 | Packing and Palletizing -2 robots

9 | Single Line Palletizer – CASE2CUBE

10 | Multi-line Palletizer

11 | Palletizing Calculator

13 | Case Packing

14 | Customer Service

15 | About Motion Controls Robotics

Packing & Palletizing 2

 Note from Motion
Controls Robotics
M any manufacturing companies are looking to improve their
manufacturing processes, but they are finding the upfront cost of adding
robotics to be prohibitive. This is the main reason Motion Controls
Robotics focuses so much effort on trying to find innovative ways to solve
robotic packing and palletizing issues cost effectively.

As robotic solutions are becoming more affordable, even small

companies are starting to see that integrating these flexible robotic
solutions into their process allows them to be even more competitive while
staying financially strong.

MCRI has developed standard, yet flexible solutions for case packing and
palletizing a variety of products. This E-book will review the best options
for implementing a case pack and palletizing system.

Motion Controls Robotics focuses on robotic material handling applications such as

picking, packing, and palletizing for a variety of industries. When we started the
company in 1995, our goal was to find ways to keep American manufacturers
competitive through integrating robotic solutions that maximize process efficiency.
Today, this mission is still extremely important because keeping manufacturing
facilities from moving overseas only improves the overall economy.

Packing & Palletizing 3

 Packing & Palletizing
Packing and palletizing product is our specialty.
Even if you have multiple sizes of product or cases, we are able to pack
these products and send them to a palletizer.

We are also able to

palletize a variety of
products without case
packing. This allows us to
solve any end-of-line
requirements your
company may have. The same robot palletizing both cases and rolls as
they come in from different infeed conveyors.

From case palletizing to bags, rolls, slit As far as integration goes,

rolls on end, mixed caseload palletizing Motion Controls Robotics
as well as other challenging palletizing
does a fantastic job. They
requirements, Motion Controls Robotics
were on target every time
has successfully handled it. Motion
Controls Robotics develops robotic
and never leave you
palletizing systems that are highly hanging. The projects are
reliable and flexible enough to handle on schedule, on budget and
various configurations all while allowing the engineering works right
process adjustments on the fly. the first time.
~ Flexcon Industries

Packing & Palletizing 4

Interactive E-book – click on the robot above to learn more about each
robot’s capabilities

FANUC America offers a variety of robots for picking and packing

applications. Picking and packing robots have a variety of reach and
payload options to accommodate each process.

FANUC robots offer useful software technologies for specializing and

perfecting the robotic pick and pack application. Advances in vision
sensor technology and integration allow FANUC’s iR Vision option for less
expense with 100% quality testing, higher picking rates, picking from a
moving conveyor belt, identification of part orientation, and many other
beneficial functions.

Packing & Palletizing 5

Interactive E-book – click on the robot above to learn more about each
robot’s capabilities

FANUC America offers a variety of robots for palletizing applications.

These robots all have software and vision options available to increase
the flexibility and fine tune the process. Designing the cell by looking at
future needs helps to make your robots reusable and re-deployable if
there are product changes.

Palletizing robots generally offer a 4 – 6 axis design.

A flexible palletizing system can increase your throughput and reduce

your costs. Each application is custom designed to take into account the
customer’s process considering options such as pallet size, tier sheets,
inserts, top frames, and product order.

Packing & Palletizing 6

Packing and Palletizing -1 robot
Packing and Palletizing offers both robotic
case packing and palletizing with a single
FANUC robot. Downsize your case packing
and palletizing areas with this small
footprint, highly flexible system that is
perfect for low to medium throughput.
This complete robotic system is flexible
enough to work with a variety of product
types, weights, and sizes.

Setup of the system takes place at MCRI

The system includes complete:
with a runoff for approval and then brought
to final customer site for testing and
– Design/detail – Robot
startup.
– Fabrication – Software
Using this robotic packing and palletizing – Assembly – Electrical work
system improves:

• Efficiency – performs tasks that are

difficult for people

• Safety – completes tasks that are unsafe

for people

• Compliance - with emerging product

tracking and serialization regulations

• Flexibility – meets retail packaging

variations including variable pack counts,
variety packs, retail ready packages

• Cost savings – replaces high wage labor

YouTube Playlist

Put our experience to work for

you to increase your
throughput and reduce your
costs.
Packing & Palletizing 7
Packing and Palletizing -2 robots

Robotic case packing

and palletizing
systems can be fully
automated by adding
case erecting and
case tapers to the
beginning and end of
the packing line.

YouTube Playlist

Erected cases are placed on the case infeed conveyor and are automatically registered for packing. If
necessary, case flaps can be spread open to improve clearance into the case. Packed cases exit the
system and move downstream for robotic case palletizing.

Robotic packing and palletizing systems reduce dunnage and packaging requirements.
Manufacturers throughout North America are reducing their carbon footprint, improving their
“green” status and reducing cost with these type of robotic systems.

Packing & Palletizing 9

YouTube Playlist

Single Line Robotic Palletizer – M-CASE2CUBE

Palletizing – Base System Includes:
The M-Case2Cube System is designed
around a best in class, high-speed • Fanuc M410iB/140H • Pallet build
Fanuc M410iB/140H robot. When • Vacuum zone EOAT station
equipped with the standard end of arm for picking up cases • Exit conveyor
tool, it can handle cases in excess of 35 • 10” HMI w/ color • Infeed conveyor
lbs. at rates up to 32 cases per minute. touchscreen • Pallet rack
The M-Case2Cube is pre-engineered to • Pallet picking jaws • Safety enclosure
keep cost and lead times down.
Additionally, its compact size takes up
the same or less space than a
traditional palletizer.

Packing & Palletizing 10

 Multi-Line Robotic Palletizer YouTube Playlist

Motion Controls Robotics designed a multi-product,

multi-line palletizer with the flexibility to palletize
different product from one or more infeed conveyors
using the same end of arm tooling. The custom
designed end of arm tool can pick and palletize product,
cases, pallets, and add tier sheets & caps. The system
includes racks for tier sheets, caps, and pallets all inside
a perimeter safety fence with safety curtains on the
openings and safety stops on doors. The type of product
being palletized can be quickly selected on the system’s
HMI terminal.

Packing & Palletizing 11

Palletizing System Cost
To get you started on the path to adding a packing and palletizing system use the form
on the next page to help you estimate the cost of your robotic palletizing system.

Our goal at MCRI is keeping manufacturers competitive in the tough US market. We want to make
it easy for companies to come to us with questions regarding transforming their manufacturing
processes with robotics. To help eliminate confusion, we have developed this E-book comparing
options for packing and palletizing systems.

Palletizing systems come in a variety of shapes and sizes. Palletizing can be used for cases,
bags, containers, rolls, slit rolls on end, mixed loads, and other challenging product types. Motion
Controls Robotics develops robotic palletizing systems that are highly reliable and flexible
enough to handle various configurations.

Each FANUC robot has a base

price but this price can vary.
Some examples are:

1. Robot cost varies with the size of the

robot and its attendant servo motors
and controllers.
2. Collaborative robots have many added
features that make this a more
expensive option
3. Food grade robots and special
environment robots have higher
Ingress Protection (IP) ratings to
protect them from environmental
elements

Packing & Palletizing 12

 Level 4 Certified Servicing
FANUC Integrator
We provide innovative
robotic solutions from
concept to installation
and 24/7 service and
support for complete
customer confidence.
1500 Walter Avenue | Fremont, Ohio 43420 | [email protected] | (419) 334-5886

Calculator for estimating the cost

of your robotic palletizing system
Determine which robot you will need based on reach and capacity - robot reach and payload is available by searching through
our NEW FANUC ROBOTS product pages. (Costs below are averages for the size and series options and not exact pricing)

Small (Small Delta robot, and LR Mate Series robots)

$25,000 to 35,000 for payloads up to 7kg and reach up to .9 meters

Medium (Medium and large Delta robots, M10 and M20 Series robots)
$40,00 to $50,000 for payloads from 7+kg to 20kg and robot reach up to 1.8 meters

Large (M710, R1000, and M410 Series Robots)

- $74,000 to $85,000 for most palletizing operations with capacity from 140kg to 315kg (M410 Series Robots,
4 and 5 axis, up to 3.14 meter reach)
- $70,000 to $85,000 for most general applications with capacity from 50kg to 100kg (M710 and R1000 Series robots,
6 axis, 2.05 to 2.23 meter reach)

Other Large (R2000, and M900 Series robots)

$70,000 to $100,000 for large 6 axis robot projects with up to 360 kg payload and/or reach up to 2.65 meters

Heavy Duty (Includes the M2000 series)

For payload capacity and reaches beyond 360kg and 2.65 meters, prices change quickly ranging from $150,000 to
$400,000
Number of robots needed for the robot cell
0

Averaged cost of robot needed based on payload and reach - select FANUC robot $ 0.00

Roughly how much you can expect your robot cell to cost $ 0.00 -- $ 0.00

motioncontrolsrobotics.com

Keeping Manufacturers Competitive with

Quality Robotic Solutions
 YouTube Playlist

Motion Controls
Robotics specializes
in robotic case
packing offering
custom technologies
to eliminate errors
and improve process
efficiency and quality.

Case Packing Robot Cells

Motion Controls Robotics develops robotic case packing systems that allow product
to be automatically packed into pre-erected, lined or unlined corrugated cases.
Products are fed into the system via flat top conveyor. Erected cases are placed on
the case conveyor and are automatically registered for packing.

Portable Flexible and precise

• Cells are equipped with fork pockets or casters for easy • Handle multiple product sizes
relocation to any packaging line
• Standard corrugated and plastic/film lined cases
• Automatic tool changeover
• Precise, 6-axis servo-controlled system
Upgradeable
• infeed conveyor can attach to automated case erector • Adjust pick and place positions on-the-fly
• Completed cases can be conveyed to automated case • 200+ stored part recipes of part description,
sealers for taping pick/place locations, and stack patterns
Reduce costs
• Labor savings and a reduction in worker compensation
costs
• Reduce floor space requirements

Packing & Palletizing 14

Customer Service
Emergency Phone Support - Call 24 hours a day,
7 days a week – 877-ROBOTS2 (877-762-6872)
Once the system is installed, we have a 24/7 customer service
line for troubleshooting issues and scheduling maintenance. With
a 24hr service line, you can rest assured MCRI will be there to
provide service and support your system now and in the future.
Motion Controls Robotics is here for you to make sure you are
comfortable operating the robotic system.

We also offer:
• In-depth & FANUC
Authorized training
• System warranty
• Preventative maintenance
packages
• Discounts on spare parts

Motion Controls Robotics

services the robot with a yearly
preventative maintenance and
we haven’t had a robot failure
that caused us downtime.
~ Manufacturing Engineer

Packing & Palletizing 15

Motion Controls Robotics has been a member of the RIA since the beginning in 2005.
We joined RIA to demonstrate to ourselves and companies looking to integrate
robotics that we are a robot integrator that strives for and is committed to constant
innovation and highly values robotic safety issues.

"At times it can be difficult to convey to a new

customer the depth of experience and qualifications
of our organization. Achieving the Robotics Industries
Association certification demonstrates our expertise
and allows our customers to make a more informed
supplier selection decision based on the findings of
an independent third party."

Scott Lang, President, Motion Controls Robotics, Inc.

(First ever to achieve RIA certification.)

Packing & Palletizing 16

 Motion Controls Robotics is a leading provider of automation solutions to manufacturing
industries since 1995. The company provides full service robotic solutions from concept to
installation and service/support that keep manufacturers competitive. Motion Controls
Robotics creates solutions for Fortune 500 and small to medium-sized manufacturers in
general industries, plastics, food, building materials and tier one and two automotive
suppliers. They also automate small production shops and machine job shops. Motion
Controls Robotics provides automation solutions to manufacturers for a variety of
applications including material handling (case packing, palletizing and machine tending),
material removal, sanding, deflashing, arc welding and vision-guided systems.

Motion Controls Robotics’ northwest Ohio headquarters is located at 1500 Walter Avenue,
Fremont, Ohio. For more information, visit www.motioncontrolsrobotics.com.

Keeping Manufacturers Competitive with

Quality Robotic Solutions