marosol

Solution thumbnail

Process layout

Process Overview

This deployment was implemented at Yuhan-Kimberly’s Chungju Plant, delivering an integrated solution that combines a Yaskawa industrial robot with a strapping-cut workbench to automate depalletizing + strap cutting.

The customer pursued a depalletizing system to reduce labor costs and operator fatigue, and showed strong interest in automating strap cutting and strap discharge to further maximize cost savings and operational efficiency.

The solution handles mixed carton sizes by aligning (squaring) cartons, cutting and removing straps, and then feeding cartons into the case packer. This improves throughput and consistency in both carton infeed and strap removal, while reducing physical strain on operators and enhancing workplace safety.




Project Background and Objectives

At Yuhan-Kimberly’s Chungju Plant, cartons arriving on pallets were previously broken down manually and then loaded one-by-one into the case packer. The work was highly repetitive, and manual strap removal using knives created a persistent risk of safety incidents.

The objective of this project was to minimize reliance on manual labor by automating the entire process—from depalletizing through case packer infeed—and to achieve lights-out (unmanned) operation for strap cutting. This enables improved operator safety, reduced fatigue and staffing burden on the floor, and more stable, repeatable plant operations.

Components

Robot

Yaskawa GP50 Industrial Robot: A high-speed, high-precision 6-axis articulated robot optimized for palletizing/depalletizing operations. It can automatically pick, place, and transfer a wide range of products, making it well-suited for industrial automation.

Peripherals

Carton Aligner + Strap-Cutting Station: A workbench system that squares/aligns cartons of various sizes, then cuts and evacuates strapping. Safety Light Curtain + Perimeter Fence: Visually separates the operator zone from the robot cell. If an operator enters the depalletizing area, the system immediately stops motion to ensure safety.

Workflow

STEP 1.An operator loads a pallet of stacked cartons into the designated loading position
STEP 2.The operator selects the carton “recipe” on the HMI (OP panel) and starts the cycle
STEP 3.The robot depalletizes bundled cartons per the selected recipe and transfers them to the alignment/strap-cutting station
STEP 4.The station squares the bundle using servo drives and pneumatic cylinders
STEP 5.The system cuts the straps while the cartons are securely clamped in position
STEP 6.A hook mechanism captures and discharges the cut straps
STEP 7.The station re-squares the bundle to prevent misalignment during cutting
STEP 8.The robot feeds individual cartons to the case packer infeed one by one.

Features

Key Features

  • Flexible handling across multiple carton sizes: Alignment and strap cutting can be performed regardless of carton size, supporting up to 27 carton size variants.

  • Flexible inbound conditions: Even if the number of strapped cartons on the pallet varies by load, the operator can simply enter the required conditions on the HMI (OP panel), and the robot can execute depalletizing accordingly.

Deployment Benefits

  • Higher productivity: Depalletizing and strap cutting are automated, increasing operation speed and reducing operator fatigue.

  • Lower operating cost: Process automation enables labor reduction and more efficient operations.

  • Improved safety: Safety light curtains, safety mats, and laser scanners help minimize accident and hazard risks during operation.

Results

Key Benefits
This depalletizing and strap-cutting automation solution deployed at Yuhan-Kimberly’s Chungju Plant delivered meaningful improvements across productivity, safety, and workforce utilization. Previously, the process required 2–3 operators to manually break down palletized cartons and remove strapping
after automation, the cell could be operated with a single operator primarily monitoring the system, resulting in a labor reduction effect of over 50%.
Client Feedback
The customer commented, “By deploying the depalletizing robot, not only was the operator’s physical workload reduced, but logistics efficiency also improved significantly. With the safety system well implemented, operators feel more secure and can stay focused on their work.”
Banner image

Unauthorized copying or reproduction of any content on Marosol may violate the Unfair Competition Prevention Act and Copyright Act.

Yuhan-Kimberly’s Choice: Fully Automated Depalletizing + Strap Cutting📦

Application Field
Industry > Textile·Paper, Sector > Manufacturing

Curious about the robots used?

Recommended Solution

Metal Machining Machine Tending for Three WIA MCTs using Yaskawa Robots

Metal Machining Machine Tending for Three WIA MCTs using Yaskawa Robots

This machine tending automation solution utilizes a YASKAWA industrial robot to automate the loading and unloading of metal workpieces for three WIA MCT (F410D) units. In the traditional process, operators had to stand by the machines constantly to manually feed workpieces. By delegating the loading and unloading tasks to the robot, operators can now focus on overall equipment management and system operation, significantly increasing operational efficiency. Furthermore, by having a single robot service three machining centers, productivity is maximized across the entire production cell.

Favorites
Smart Machine Tool Assistant "G-AiD" using Collaborative Robots

Smart Machine Tool Assistant "G-AiD" using Collaborative Robots

This machine tending solution automates the loading and unloading of parts by integrating three G-AiD small-precision (4-axis) machine tools with a Universal Robots UR10e. By arranging multiple machine tools in a compact space, a single robot can manage the entire workflow, significantly boosting operational efficiency and productivity. G-AiD features an Automatic Tool Changer (ATC) and tool wear sensing, enabling efficient task management. Furthermore, its seamless data integration with external systems makes it an ideal candidate for Smart Factory government support projects, helping to reduce initial investment costs. The project was implemented to resolve labor shortages in part machining, reduce personnel costs, and enable real-time quality monitoring and improvement through smart factory integration.

Favorites
Aluminum Dross Processing using Yaskawa Robots

Aluminum Dross Processing using Yaskawa Robots

This automation solution utilizes YASKAWA robots to automate the hazardous manual process of handling high-temperature aluminum dross (a byproduct of molten aluminum). By deploying a robot with high heat resistance, this system replaces human operators in extreme thermal environments, ensuring workplace safety and enabling continuous, non-stop operation. The primary goal of this project was to enhance operational safety and improve the work environment by automating the byproduct treatment following high-heat aluminum processing.

Favorites