Robots on the rise

25 March 2009



It’s undeniable that robotics in packaging are making their presence felt. This article from the US-based PMMI discusses the reasons for this and the wider implications.


Ironically, although the high initial investment cost has hindered past growth of robotics for packaging functions, it may be cost savings on the packaging line itself that will spur future sales. A further irony: whilst many user companies purchase robots to reduce labour, they require additional skilled labour for operation and maintenance. However, the overall perception among robot users is extremely positive; virtually no-one regrets the investment made in robots. Furthermore, their use for packaging functions is accelerating - 9.5 per cent of all packaging lines used robotics five years ago, reaching 17.4 per cent today. The figure is projected to be 41.7 per cent in five years.

These are among many findings in a 2008 study from PMMI entitled ‘Robotics: Usage and trends in packaging applications’, whereby 300 equipment manufacturers and packaging companies were surveyed to piece together an accurate snapshot of the current and future robotics landscape.

Current state of play

Of the survey participants, one-third represented machinery manufacturers and two-thirds are consumer packaged goods (CPG) companies who buy machinery. Half of the manufacturers reported they currently provide robotics, but of the half that do not, 10 per cent say they will do so within the next five years. Involvement with robotics is less prevalent amongst CPGs than manufacturers: 22 per cent report robots at work on their packaging lines, and 21 per cent say they will add robots in the next five years. A little more than half of end-users (57 per cent) indicated no interest in robots.

The perception among robot users is quite positive: 80 per cent of the CPGs rate robots as very important or extremely important to the success of packaging operations. Amongst the food companies, 50 per cent of respondents rated the robots as extremely important. Durable goods companies also have a very high regard for robots. Although it would be expected that people who have already invested in the technology would rate them highly, the degree to which this is the case reveals the importance placed on the functions performed by robots.

How important are robots?

Perhaps the reason for such high opinions is attributable to the fact that robots are doing their jobs so well – 98 per cent regard their installed robots as successful. Of these, 57 per cent regard their robots as ”extremely successful.” The tiny minority that are less than happy seems to indicate problems very specific to their operation, such as the robot experiencing difficulty picking up bags.

The success of robots

The largest subset of packaging companies evaluates performance success based on speed and throughput. Also considered in the evaluation are flexibility, overall cost savings (especially in relation to labour costs), reliability and efficiency. Amongst those who are considering a future robotics investment, speed and throughput have the highest priorities, followed by accuracy and efficiency.

Overall, almost all of the reasons named for using or adding robotic capabilities relate to money — either reduced costs or increased production and revenue.

Surveyed packagers reported that their companies invested between $30,000 (£20,960) and $1.2mn (£83,8316) on robotic installations. The average cost is just over $375,000 (£262.000). Most companies say payback has taken between one and three years.

Where are robots used?

According to the packaging companies, palletising/depalletising is the most common function for robots, followed by conveying/placing, case/tray-packing and cartoning. The tabulations are almost identical to manufacturers’ responses as to the types of robots they most often sell. Several other functions are mentioned in this question - such as inspection/detection or labelling - but the number of responses drops off significantly past those top four functions.

All types of robots are in use on packaging lines. The four-axis robot is definitely the most common, however, accounting for half of all installations. Delta, Gantry and SCARA robots are each reported at about 25 per cent usage, and about 15 per cent of companies have six-axis robots (the remainder currently are bespoke robots). More than 40 per cent of users say they never reprogram their robots. Nearly one-third (31 per cent) say they reprogram their robots an average of once a year. Another 29 per cent reprogram more often, some up to 20 times per year. When reprogramming does become necessary, 40 per cent of participants claim it is undertaken online.

More than machines

Robot manufacturers strive to be supportive and responsive, so the packaged goods companies can look to them for help when needed. More than 90 per cent of robot makers provide installation services, and 80 per cent offer maintenance services. Three-quarters of manufacturers also provide engineering and design work, although the smaller firms are more likely to outsource this function so it is available to the buyers. Several survey participants suggest equipment manufacturers may be able to help packaging companies with estimating cost-savings and payback, together with offering financing options that go beyond that which is offered with other machinery - anything that can help the packaging companies get past that initial investment hurdle. Companies need to build a cost justification model that includes labour savings, improved ergonomics and increased productivity, together with maintenance and training.

The main benefits

Manufacturers are quick to sing the praises of robots over other fixed equipment, but by far the leading benefit mentioned is flexibility and versatility. The second benefit robot makers cite is reliability, as measured by Mean Time Between Failure. Also mentioned by a few respondents are small factory footprints and low maintenance requirements.

Whilst generally agreeing with the manufacturers’ opinions, the surveyed CPGs are more likely to praise their robots’ operational characteristics, such as reliability, dependability and consistency of performance. Cost-savings are also on the list, especially as they relate to labour. Also related to labour are the ergonomic advantages of letting robots do the heavy lifting, so to speak. One participant pointed out that “Robots don’t complain.”

The downside

But the picture is not entirely rosy, according to the packaging companies. Aside from the steep initial investment, robots require a higher technical level of maintenance and supervision than most other equipment and, therefore, a higher level of skilled labour. Also, whilst there’s an ergonomic advantage for workers, a robot can also present a safety hazard, often requiring guarding to protect operatives from accidentally wandering into its path. One respondent further pointed out that, in many cases, a single robot performs end-of-line functions for multiple packaging lines. Hence, if that robot goes down, so do all of the lines feeding it.

Robot manufacturers recognise the shortcomings, especially the financial hardship of high initial investment and ongoing skilled maintenance. Several manufacturers also point out that robots are unsuitable for handling all package types, so a robotic installation is not recommended for every application.

Looking ahead

The growth in robotics use for packaging functions is accelerating. Packaging machinery manufacturers reported using robotics in 17.4 per cent of the lines they build or collaborate on today, and predict that this will grow to 41.7 per cent in five years. Yet more revealingly, 77 per cent of the CPGs who currently use robots expect to expand those applications over the next five years.

Packaging companies and manufacturers differ in their projections for which part of the packaging line - primary or secondary - will grow fastest over the next three years.

Of course, growth is seen in applications already using robotics, such as palletising/depalletising and case packing. But manufacturers also cite vision systems as a future growth target, and they see secondary packaging lines growing at a slightly faster rate than primary packaging functions (57 and 46 per cent, respectively).

This focus on secondary packaging growth may account for why case packing and palletising — secondary and tertiary — could trigger a need for robotics. However, the CPGs in the study say primary packaging is growing faster, at 54 per cent over the next three years vs. 38 per cent for secondary packaging. Regardless of whose crystal ball is most accurate, study respondents agree that growth is forecast for the packaging robotics industry as a whole.


Palletising/depalletising is the most common function for robots The Bosch Sigpack Delta robot in use for pick 'n' place applications

Palletising/depalletising is the most common function for robots Palletising/depalletising is the most common function for robots
The Bosch Sigpack Delta robot in use for pick 'n' place applications The Bosch Sigpack Delta robot in use for pick 'n' place applications


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