PROCESS AUTOMATION
Automate packaging and sorting.
Sort products automatically and load cartons or trays. We match detection, grippers and conveyors to your products, including format changes and handovers within your line.
TYPICAL CHALLENGES
Product flow and controlled handovers.
Spacing, position and quantities vary in a moving product flow. We assess peak loads, delicate products and occupied destinations, then coordinate detection, grippers and buffers.
01
PRODUCT FLOW
Product flow, orientation and line speed
Cameras, encoders and queue logic capture spacing, orientation and occupancy within the moving product flow.
02
ALTERNATIVES
Recipe and format changes
Different products, packing patterns and packaging formats require rapid recipe changes, adjustable guides and flexible gripping technology.
03
PRODUCT PROTECTION
Gentle handling at high line throughput
Gripping force, vacuum, acceleration and placement motion are adapted to sensitive surfaces, soft products and unstable packs.
TECHNICAL SOLUTION CONCEPT
Packaging and sorting in the product flow.
We combine product detection, conveyor tracking, robot coordination and packaging supply. The cell responds to variants, missing products and occupied destinations without disrupting the overall line flow.
01
Detect product orientation, variant and quality characteristic before picking
02
Track moving conveyors synchronously using encoders and cameras
03
Engineer grippers and multi-pick handling for the product and target packaging
04
Control buffers, sorting sequence, rejection and format changes
ENGINEERING CRITERIA
Line capacity, packing patterns and format changes.
Packaging automation requires a manageable product flow and defined handovers. Delicate products, peak throughput and format changes determine the design. Grippers, tracking, packaging presentation and buffers shape cost.
01
LINE THROUGHPUT
Product distribution over time
Peaks, gaps and product clusters determine the number of robots, pick windows, buffers and multi-pick strategy.
02
PACKAGING
Carton or tray supply
Erecting, feeding, positioning, fill level and onward transport must be interlocked with the robot.
03
HYGIENE
Cleaning and material requirements
Food, pharmaceutical and dusty products influence robot specification, grippers, surfaces and cleanability.
04
CHANGEOVER
Required format-change speed
Recipe changes, automatic adjustment and tool-free changeover reduce downtime between variants.
HOW WE WORK
Trial picking and packing in the actual product flow.
We record products, packaging and quantity distributions, then assess critical picking and placement steps. Production trials also cover conveyor stops, missing products and format changes.
01
Capture the product and packaging matrix
We record formats, surfaces, packing patterns, line speeds, peak loads and changeover frequency.
02
Simulate picking and line flow
Vision, pick windows, robot count, buffers and grippers are engineered using real product distributions and peak loads.
03
Commission formats and fault scenarios
During production trials, we test missing products, occupied destinations, conveyor stops, format changes and controlled restart.
Planning your application
Questions about packaging automation and sorting.
Packaging automation connects product flow, detection and controlled placement. These questions help match the solution to changing formats, delicate products and existing lines.
- Typical tasks include sorting products by defined characteristics and placing them in an ordered pattern in cartons or trays.
- A single repeated manual step can also be automated when feeding and handover conditions are suitable.
- NIKLAS Vision Check is a cell for optical inspection and sorting. Packaging itself is assessed as a separate task.
- We assess conveyors, product handovers, packaging supply and signals from the existing controller.
- A fixed handover can use feeding and permission signals. Picking from a moving conveyor requires synchronised detection, conveyor motion and robotics.
- Peak loads, gaps and product spacing determine picking windows, buffers and the required number of robots.
- Cameras or sensors detect position, variant and the characteristics needed for the sequence.
- Sorting criteria and handling of rejected parts are agreed with you. Occupied destinations and missing products receive defined handling sequences.
- Delicate products are handled using suitable contact areas, gripping forces and placement motions.
- Products, packaging and packing patterns are recorded in a format overview.
- Recipes, guides and grippers are designed for these variants. Some formats require adjustments or tool changes.
- Format changes are tested using representative products and packaging, including handovers to adjacent stations.
- Supplying packaging material, changing formats, cleaning and maintenance remain part of operating the system.
- Grippers, conveyors and sensors need regular checks. Cleaning and material requirements are assessed for your products.
- The system sequence is tested with conveyor stops, occupied destinations and missing products to support a controlled restart.
- Photos or a video of the current process show feeding, manual steps and handovers.
- Useful details include product and packaging samples, dimensions, weights, packing patterns, quantities, conveyor speed and format changes.
- Send the information you already have. We will work through any missing data or open requirements with you.
SERVICE & SUPPORT
Service for packaging and sorting systems.
The scope of service is aligned with the installed technology, shift pattern and your maintenance organisation.
01
Handling and conveyor technology
Inspect grippers, conveyor technology, sensors and transfer points.
02
Formats and recipes
Coordinate format changes, system recipes and cycle performance with the process.
03
Wear and safety
Maintain wear parts, program versions and safety functions on schedule.
DISCUSS YOUR PROJECT WITH US
Assess packaging and sorting for your production.
Send product and packaging samples, a format overview and a video of product flow, including line throughput and changeover frequency. We assess handovers, gripping and the packaging sequence.