Case study: Big Bag / Bulk - Handling by means of robots

One of the advantages of robotics in addition to its good payback is its ergonomics. Heavy lifting leads to physical wear and tear. Among the most difficult for humans to handle are big bags, also called bulk. This is true both in terms of their weight and the body movements that occur during handling. Recently I was at a manufacturing company. Many years ago, this company had a coordinated plant built for a lot of money. At the beginning of the plant there is a mixer, which originally received the material only through silos. Over time, however, the product to be manufactured was constantly modified, also as a result of environmental requirements, so that the recipe (bill of materials) was changed. Now there are more raw materials/ ingredients than silos. As a result, employees have to empty big bags by hand more or less continuously. Time to look for automation solutions using robotics.

Opening and emptying big bags

For laypersons: When selecting the right robot, the cycle time plays a major role here in addition to its payload and reach. If emptying is done permanently, a classic industrial robot separated by fences probably makes sense. If a big bag is emptied only sporadically and the system is still to be easily accessible, or if the space conditions are too tight anyway, a cobot becomes all the more interesting. Safety can be ensured with light barriers, radar and other sensors. To basically show how easy it can be, especially when filling from top to bottom, a video (unfortunately with terrible music):

Bulk filling

There are two main points to consider here: The delivery of the empty bags, then the attachment to the filling station and the closure of the bulk. Solved here as an example:

Palletizing big bags

Palletizing of goods is also possible on a rental basis by means of standard solutions. Here is one example of many. Of course, it can also be done in a more space-saving way. The other processes appear to be more important here:

Conclusion:

Subsequent solutions are also generally possible. The investment requirement is quite different. Depending on the task, monthly expenditures instead of a one-off amount are possible. This is especially true for standardized solutions, which can be reused elsewhere by the supplier if necessary. Either way, robotics usually pays for itself very quickly and offers additional benefits such as ergonomics and consistent quality.

Are we networking? LinkedIn
-> Go to the Cobot group on LinkedIn (link). The author is also a consultant (robotics, tech & finance). Hardly anyone is likely to have a comparable market overview. Thanks to government funding, SMEs have the option of a company tour with concrete recommendations etc. for a flat rate of €1,500 incl. travel.