If you’re a food producer, whether an ambitious SME or a global brand, your first step into automation should be a holistic approach. Value comes from a complete, well-engineered solution built around four core functions. Get this right first, then tailor the rest to the specifics of your operation.

As a leading manufacturer of robotic packaging solutions dedicated to the food industry, PWR designs tailored and plug and play solutions considering these four fundamentals:

 

1) Product identification

 

Goal: eliminate waste and maximise sellable product packed

 

To package 100% of sellable product, the system must first identify and understand what’s on the line. Identification can be as simple as beam sensors or as advanced as 3D vision. Whatever the technology, it has two jobs:

 

1. Determine the position and orientation of each product so robots can pick accurately at speed.

 

2. Confirm if the product is good or not so only compliant items are packed.

 

The first is about precision. Better positional accuracy = higher pick success.

The second needs clear, black-and-white definitions. What good looks like must be agreed up front with your automation partner to avoid false rejects (lost yield) or false positives (quality escapes). When engineered well, product identification prevents waste and drives lifetime value.

 

2) Product distribution

 

Goal: ensure sellable product is packed and every pack is complete.

 

Robots are reliable and precise when paired with software that gives them clear instructions. The control software turns identification data into actions: which robot picks which item, when, and where it gets placed.
When designing full solutions, we need to consider the following;

 

• Multiple robots working in parallel

 

• Product and packaging conveyors at different speeds/directions

 

• integration and synchronisation with other equipment

 

• Late product arrivals, gaps, and surges

Here, the distribution logic must run robust, real-time algorithms to balance loads, prevent collisions, and fill every pack without rejecting sellable product.

 

3) Product handling

 

Goal: design a flexible solution with minimal downtime

 

Every robot needs the right “hand” which is the gripper, end-effector, or EOAT. The gripper is the only part that touches the product, so control, speed, and care must always be part of the consideration, especially when handling delicate or highly decorated products.
The combination of the robot and gripper must successfully;

 

• Protect product integrity

 

• Maintain a secure, stable grip from pick to place

 

• Meet hygiene standards for food environments

 

• Adapt to format, size, or recipe changes (using quick-changes to tools if required)

 

A well-considered robot and gripper combination will ensure a fast and gentle system that protects your products.

 

4) Operator interaction

 

Goal: Ensure the solutions are easy to use and system training is easy to access.

 

Solutions will always underperform if the human interface is confusing for your team. Operators, engineers, and hygiene teams must be able to find and extract the information they need in order to carry out their roles. When looking at integrating automation, we recommend that the following are considered;

 

• Clear and easy to use HMI with views for multiple job functions

 

• Open, accessible machine design for cleaning and maintenance

 

• Staff training and ongoing service support from your supplier

 

• Actionable diagnostics tied to specific KPIs like waste

 

• A people first design that allows your team to handle things like recipe changeovers, and protects lifetime value.

 

Once you’re confident that your chosen supplier can deliver on identification, distribution, handling, and operator experience, then you can consider the tailored elements of your specific solution.

 

 

Why PWR?

 

PWR specialises in robotic packaging solutions for the food industry. We are the trusted partner to food manufacturers worldwide. If you’re exploring your first automation step, or scaling to multi-robot lines we can help you validate the essentials and design a tailored solution that fits your products, plants, and growth plans.

 

Ready to begin? Contact one of our experts today.