Palletizing of 20kg Beverage Boxes using Yaskawa Robots

Industry > Food·DrinkSector > ManufacturingSector > Logistics

This heavy-duty palletizing solution utilizes the YASKAWA MH180, a specialized palletizing robot, to automate the stacking of 20kg beverage boxes, handling up to two boxes at once (40kg).

By replacing human workers for these high-load tasks, the system prevents musculoskeletal disorders and significantly boosts productivity by handling up to 40kg in a single motion. Furthermore, the robot achieves high transport stability by stacking products in a tightly-packed, staggered (zigzag) pattern, just as a skilled manual laborer would.

Components

Robot	Robot: YASKAWA MH180 High-payload 6-axis articulated industrial robot. Payload: 180kg Reach: 2,702mm Weight: 1,020kg Repeatability: ±0.07mm

Workflow

STEP 1.	Infeed: Either one or two beverage boxes are fed into the picking station.
STEP 2.	First Layer Palletizing: The robot stacks 8 boxes to complete the first layer.
STEP 3.	Multi-Tier Stacking: The process repeats until 3 tiers (layers) are successfully stacked.
STEP 4.	Discharge: The fully loaded pallet is discharged for transport.

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Key Features

Stable Handling and Stacking Operations

Optimized Stacking Patterns: Performs staggered (cross-stacked) and tightly-packed stacking by layer to ensure maximum stability during transport.

Dual-Securing Mechanism: Features a specialized gripper that secures heavy workpieces from both the sides and the bottom, ensuring safe handling without the risk of dropping.

Simultaneous Productivity Boost and Ergonomic Improvement

Dual-Box Handling: Maximizes throughput by handling up to two workpieces (40kg) simultaneously.

Labor Safety: Minimizes idle time and completely eliminates the risk of musculoskeletal disorders for workers by automating heavy lifting.

Custom Design and Pre-Verification

Optimized Tooling: Custom end-of-arm tooling (EOAT) is designed and manufactured based on specific load requirements and facility conditions.

Simulation-Based Validation: Conducts 3D simulations to perform interference checks and verify cycle time performance before on-site installation.

Implementation Results

ROI Period	24 months
Key Metrics	Increased productivity through continuous, non-stop operation. Reduced cycle times by handling two heavy workpieces at once.
Client Feedback	High-load tasks are physically exhausting and were often avoided by workers. By automating these heavy lifting duties, we removed the physical burden from our staff and significantly increased our overall productivity by shortening work times.