SUCCESS STORY
FULLY AUTOMATED CASE PACKING SYSTEMFROM SINGLE MACHINE TO FULLY AUTOMATED CASE PACKING SOLUTION
A fast-growing co-manufacturer approached SIGMA Integration for a single machine — a drop packer — to pack their canned beverages into cases, but after an on-site evaluation and a deeper understanding of their production goals, SIGMA delivered a complete, fully integrated packaging system that streamlined their entire end-of-line operation.
This tailored, automated system not only fit the client’s compact floor plan and met their production rate, it also kept labor requirements to a minimum, ultimately saving money in the long term.
The Challenge
SCALING CASE PACKING EFFICIENCY
The client had optimized the upstream part of their beverage line, as the canned product was already being filled and sealed. What they needed next was a fully automated solution that included case erecting, case packing, and case sealing. Their objective was to pack cans in a 4×3 pattern, three layers deep, into each case. To do this manually, the client estimated they’d need at least five operators on the floor.
This project wasn’t just about finding the right equipment — it was about providing a solution that could produce 15 cases per minute, fit a tight footprint, and be fully operational in only 4 months.
The solution
REDESIGNING THE APPROACH
After visiting the facility, SIGMA Integration stepped back from the initial request for a drop packer and took a holistic look at the problem. Our engineering team determined that a robotic pick-and-place solution would be far more effective, given the can size, case format, and speed targets.
THE SPEED OF SIGMA’S IN-HOUSE INVENTORY
Instead of long lead times that the client didn’t have time for, SIGMA pulled from its 660,000-square-foot ready-to-go inventory. The robotic case packer, case erector, and case sealer were all in stock, and this allowed the project to move forward without delay.
CUSTOM ENGINEERING FOR A PERFECT FIT
SIGMA’s engineers custom-designed the conveyor system to match the client’s limited floor space and collaborated with their preferred conveyance vendor to expedite delivery. Additionally, modifications were made to the robotic end-of-arm tooling to perfectly accommodate the client’s unique cans.
The RESULTS
SIGMA Integration delivered a fully automated end-of-line packaging solution tailored to the customer’s needs — all under the original timeline.
By integrating three key machines with a centralized control panel and custom conveyance, SIGMA provided more than just the equipment. They delivered a complete system that enhanced productivity and reduced the need for additional labor.
What began as a simple drop packer request evolved into a fully integrated, space-optimized solution that not only met the client’s goals, but reshaped their end-of-line production through automation — exceeding expectations.
Production Rate
15 cases per minute; 360 cans per minute
Labor Savings
Reduced labor of 5 manual operators
Turnaround Time
Under 4 months
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