Clients:
BIMBO BAKERIES USA
Category:
Projects
Project: Direct-to-Truck Bread Bagging Machine (ALL-IN-ONE)
Description
Previously, the operation required four manual processes carried out by different operators:
- 1. Unload the tubs and place them in position from a height of approximately 2 meters.
- 2. Arrange the product and place it in the bins, then restack them rotated 180° to prevent damage to the product.
- 3. Remove debris and trash that has accumulated in the tubs.
- 4. Manually transport the bins containing the product, once they have been stowed, to the distribution truck.
This system resulted in high labor demand, ergonomic risks, and prolonged operation times, which represented a clear opportunity to optimize the process.
Objective
An automated solution was designed and implemented to replace the four manual processes, enabling a more efficient and secure workflow. This change yielded key benefits:
- Reduction of ergonomic risks by eliminating repetitive movements at heights of up to 2 meters.
- Optimization of operating time, reducing delays in the preparation and stowage of vats.
- Standardization of product quality, preventing damage to the bread through controlled and precise handling.
- Increased productivity by freeing up operators to perform higher-value tasks on the production line.
This implementation not only improved the safety and efficiency of the process but also ensured greater reliability in the distribution of the final product.
Participation
- Analysis, design, and programming of a control system using Karel, the native programming language of Fanuc robots.
- Configuration and parameterization of a Balluff IO-Link master module.
- Configuration of Powerflex variable-frequency drives to control the four motors that powered the system.
- Creation and programming of safety zones on an Allen-Bradley safety scanner.
- Control and coordination of 3 robots and a servomotor operating in the same cell.
