Lineup of FANUC SCARA robots on an automated production line

Precision Packaging Automation: The Ultimate Production Line

Flexible Automated Systems for High-Speed Production

When a new customer needed a high-speed automated solution for their ink fulfillment process, they turned to SDC—a recognized leader in complex automated machines. A key robotics supplier for SDC, FANUC, pointed them in our direction because of our expertise in robotic integration, advanced controls engineering, and automated material handling.

SDC’s years of experience as a FANUC Authorized Systems Integrator (ASI) and reputation for successfully designing complex automated machines with robust control systems made us the clear choice for this project. By leveraging our library of pre-engineered products with a streamlined project management process, we successfully delivered a reliable, cost-effective, and scalable solution that met our customer’s demanding requirements.

Technical Components & Technologies

12 FANUC SCARA robots
SDC servo-controlled box erectors
SDC tray handling systems
30+ servo motors
SDC’s new Ignition-based HMI with Allen Bradley PLC
SQL Server to integrate with our customer's software for real-time data management
30 Cognex DM374 barcode readers
Mettler Toledo Bench Platform PBA436 and Weighing Terminal IND360
Precision Packaging Automation Video Thumbnail
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Robotic pick-and-place station with SDC tray handling on a production line.
Automated media feeder integrated on a production line
Large-scale Automated Production Line with FANUC SCARA robots at their pick-and-place stations.
Rotary cardboard box supply for automated cartoning and packaging
Integrated SDC servo motor on an automated production line
Cartoning and packaging technology integrated onto a machine
Tray handling platform waiting for a box to be loaded
Automated sortation system at the end of a production line.
Robotic pick-and-place station with SDC tray handling on a production line.
Automated media feeder integrated on a production line
Large-scale Automated Production Line with FANUC SCARA robots at their pick-and-place stations.
Rotary cardboard box supply for automated cartoning and packaging
Integrated SDC servo motor on an automated production line
Cartoning and packaging technology integrated onto a machine
Tray handling platform waiting for a box to be loaded
Automated sortation system at the end of a production line.

The Machine Concept:

Our new customer required an automated material handling and processing system capable of assembling and packaging ink cartridge replenishment kits at high speed. The key challenges included:

  • Ensuring seamless robotic integration with real-time data tracking.
  • Managing high-volume, variable order fulfillment with minimal downtime.
  • Automating the handling and packaging process efficiently.
  • Maintaining speed and precision while keeping costs in check.

Solution: Adaptive Production Workflows Meet Cutting-Edge Technology

In the rapidly evolving landscape of manufacturing integration solutions, SDC has pioneered a breakthrough approach to ink cartridge fulfillment. Our adaptive production workflows leverage advanced robotic material handling technologies to transform traditional packaging processes. To meet our customer’s needs, SDC deployed a fully integrated, high-speed fulfillment system incorporating the following technologies:

  • Robotic Integration: 12 FANUC SCARA robots synchronized with SDC’s 2-axis servo-controlled pick-and-place systems for precise material placement.
  • Tray Handling System: A modular, high-volume tray system designed to optimize ink cartridge part feeding supply.
  • Automated Box Erection & Packaging: SDC’s servo-controlled box erector for fast, reliable small box formation.
  • High-Speed Labeling & Sorting: 30 Cognex DM374 barcode readers and vision systems ensuring accurate product tracking and verification.
  • Real-time Data Tracking & Order Management: SDC’s new Ignition-based HMI and SQL server integration with our customer’s software for real-time data management that facilitates live production monitoring and seamless workflow adjustments. There are two large overhead monitors and seven HMI touchscreens that engineers can connect to from their desktops and view machine operation and status.
  • Error Reduction & Quality Control: Mettler Toledo Bench Platform PBA436 and Weighing Terminal IND360 for precision weight measurement and verification.
  • Scalable Design: Modular components allowed for future expansion and customization as our customer’s needs evolve.

Results & Business Impact

 

This is operational efficiency optimization in action. The implementation of SDC’s automated solution resulted in significant operational improvements. By integrating advanced technologies, we’ve created a system that:

  • 10x Increase in Order Fulfillment Speed: Achieved through synchronized, high-speed automation.
  • Seamless Data Integration: Real-time tracking and error reduction with our custom Ignition software that communicates with our customer’s SQL server database and the PLC.
  • Error-Free Fulfillment: Advanced barcode scanning and vision systems minimized inaccuracies.
  • Significant Cost Savings: Leveraging SDC’s standard components reduced engineering risk and development costs.
  • Reliable, Scalable Automation: Future-proof design accommodating evolving production needs.
Operational Workflow Diagram

Operational Workflow

Box Handling & Preparation:

  • Custom-built box erector that forms and seals branded packaging at high speed.
  • Linear indexing conveyor ensures precise electronic tracking.

Product Loading:

  • Manual bag placement station for operators to insert plastic liners.
  • SDC automated tray handling system organizes ink cartridges based on volume needs.
  • SDC Servo-driven pick-and-place technology accurately feeds each cartridge from the trays and into the automated line.
  • Barcode scanning verifies ink cartridge placement accuracy.
  • Pamphlet insertion system adds marketing and instructional materials.

Box Sealing & Labeling:

  • Flap and tuck tab closure mechanism with taping secures the package.
  • Dual-label applicators for branding and product information.
  • Automated print-and-apply labeling ensures proper shipping label placement.

Sorting & Shipping:

  • Final box transfer robot moves completed cartons to an outfeed conveyor.
  • Weighcheck ensures order accuracy before shipping.
  • Gaylord sorting system categorizes boxes for seamless distribution.

SDC Standard Products: Eliminating Engineering Risk with Proven Solutions

Pre-Engineered Automated Tray Handling System

The SDC engineering team has developed an adaptable, pre-engineered automated tray handling platform designed to complement our custom automated solutions. Built for flexibility, this platform accommodates various tray sizes, configurations, and types, including flat-wall trays. It seamlessly integrates into larger automated systems, optimizing operations and enhancing efficiency across multiple processes and part requirements.

Key Features:
  • Robotic Integration: Enables precise product loading, unloading, and quality control, reducing manual intervention.
  • Efficient Conveyor System: Over/under conveyor design optimizes workflow while minimizing floor space.
  • Content and Position Verification: Integrated barcode scanners and sensors ensure correct placement, reducing errors.
  • Flexible Configurations: Available in single or double side-by-side configurations for space optimization.
  • Tray Compatibility: Handles flat-walled and nesting trays, enhancing versatility.

SDC Pick-and-Place Systems:

The SDC two-axis, servo-driven pick-and-place is engineered for peak performance while keeping costs down, making it the ideal solution for high-speed operations. Operating in parallel with an SDC Tray Handler and Fanuc SCARA robot, each unit delivers efficient part transfer with minimal downtime.

Key Features:
  • High-Speed, Precise Motion: Servo-driven technology ensures fast and accurate part handling. This unit moves with pinpoint accuracy and incredible speed. No more waiting around – your parts will be handled in record time, with zero compromise on precision.
  • Cost-Effective Solution: The proven, pre-engineered design delivers high performance at a low cost, maximizing value. Thanks to its proven, pre-engineered design, the SDC pick-and-place provides exceptional value by maximizing output and boosting efficiency without burning a hole in the project budget.
  • Seamless Integration: This system isn’t just a standalone champion; it plays perfectly alongside other equipment, like the SDC Tray Handler and FANUC SCARA robot, working in perfect harmony to transfer parts smoothly with minimal downtime.

Custom Automated Cartoners:

Recognizing the limitations of commercially available box erectors, SDC engineered its own high-performance box erecting and packaging solution tailored to specific products, box sizes, and application requirements.

Key features include:
  • High-Speed Performance: Capable of handling up to 30 boxes per minute.
  • Indexing Linear Conveyor: Each nested box is indexed to each station down the production line.
  • Secure Carton Closure: Can glue, tape, and tuck both ends of the carton as it moves through the system.
  • Intuitive Operation: PLC-controlled with SDC’s custom Ignition-based HMI for easy operation.

The Future of Flexible Production Systems

As industries demand more agile manufacturing solutions, our flexible production systems stand at the forefront of technological innovation. We don’t just automate – we transform how businesses approach complex manufacturing and packaging challenges.

SDC’s expertise in advanced automation and robotic integration enabled our new customer to achieve a reliable, high-speed fulfillment solution. With seamless data integration, real-time order tracking, and precision engineering, SDC provided a future-proof automation system that continues to drive efficiency and accuracy in manufacturing operations.

Our key innovations in scalable automation systems demonstrate the power of high-speed precision manufacturing with automated machines. For companies seeking cutting-edge automation solutions that maximize productivity and reliability, SDC is the ideal partner. Contact us today to learn how our custom automation systems can transform your production process.

FAQ (Frequently Asked Questions):

Q: Why did this new customer choose SDC for this project?

A: One of the top robotics suppliers in the United States, FANUC, recommended SDC due to our years of experience with their robotics and our track record of success in designing complex automation systems.

 

Q: What challenges did SDC overcome in this project?

A: The main challenges included:
• Real-time order fulfillment with seamless data integration
• Precision handling of high-volume orders while maintaining speed
• Automating material handling and packaging to reduce manual intervention
• Ensuring reliable and scalable automation for future production needs

 

Q: What key technologies were used in this automated system?

A: The system integrated 12 FANUC SCARA robots, 30+ servo motors, Cognex vision systems, a Mettler Toledo Bench Platform PBA436 and Weighing Terminal IND360, Allen-Bradley PLCs, and communication between Ignition software and a SQL Server for real-time data management.

 

Q: How did SDC’s standard products reduce engineering risk?

A: By leveraging our pre-engineered tray handling systems, servo-driven pick-and-place solutions, and small box erectors, we minimized custom engineering work, ensuring a cost-effective, streamlined, and reliable solution. These proven technologies eliminated major design risks and accelerated implementation.

 

Q: What were the measurable benefits of this automation solution?

A: Our customer saw a 10x improvement in order fulfillment speed, improved real-time tracking, significant cost savings, and a scalable automation system capable of adapting to evolving production demands.

 

Q: How does the system integrate with the customer’s existing operations?

A: The machine seamlessly communicates with our customer’s software, enabling real-time order tracking, inventory updates, and automated decision-making.

 

Q: Can SDC’s solutions be customized for other industries?

A: Yes! Our automation expertise spans multiple industries, including medical devices, consumer goods, and electronics. We specialize in tailored solutions for high-speed, precision automation needs.

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