Everything runs smoothly: with the Smart Palletizer Cobot

How the palletizing robot optimizes work processes

Confectionery of all kinds goes through the packaging process at the Nagel-Group in Emleben before it makes its way to the retail trade. Every day, a considerable number of boxes are prepared for transportation. However, the task of palletizing requires precision and endurance, which makes it an exciting challenge. The introduction of a palletizing robot not only improves process efficiency, but also the working conditions of its human colleagues.

Close to the small Thuringian town of Emleben, around 150 employees work for the Nagel-Group on an area of 38,000 m², 21,500 m² of which is used as storage space. Many of them are employed in co-packaging, i.e. the assembly of cardboard displays. This is a value-added service, i.e. an additional service that Nagel-Group offers its customers alongside the transportation and storage of goods. Palletizing is also one of the additional services that customers are happy to take advantage of. The team ensures that the confectionery is reliably and neatly packaged and arrives at its intended point of sale protected accordingly. “Although the palletizing here is rather light, it is still a physically demanding task,” says Onur Yavuz, Project Manager in the Value Added Services division. “When employees change, we also face the challenge of having to retrain them. That takes time and encourages mistakes.”

Increased efficiency through technological support

The task was clear: there had to be a way to make the processes described more efficient and at the same time improve the working conditions of the employees. “The solution for us was automation,” recalls Onur Yavuz. He gained an initial impression of this via a business network, where he became aware of the Dutch company Smart Robotics and its smart palletizing offering. “After some research and discussions, it was clear to us: this is exactly what we need!” At interpack in Düsseldorf, the leading trade fair for packaging technology and machinery, he personally got an idea of the possibilities for automated processes. Extensive discussions with the team behind Smart-Robotics and the demonstration of the Smart Palletizer Cobot finally convinced him to test the palletizing robot under real conditions at the Emleben site.

It was clear that the robot had to be versatile. It had to be able to handle different types of cartons – depending on the product, the boxes have glued or pinned cardboard lids. Interchangeable suction and fork grippers ensure that any type of carton can be moved safely and efficiently. It was also important for the robot to be able to handle different palletizing patterns. After being programmed once, the cobot masters these effortlessly. With 6 to 7 movements per minute, it can keep up with the average working speed.

f.l.t.r. Uwe Friedl, Technical Operations Manager and Onur Yavuz, Project Manager in the Value Added Services division (both Nagel-Group)

The workforce is convinced

Initially, there was both enthusiasm and skepticism about the introduction of the palletizing robot. The team expressed concern that the cobot would replace the human workforce on site. Today, everyone is aware that the Smart Palletizer primarily serves to perform a monotonous but intensive task and makes the work of its human colleagues easier overall. “The employees who no longer have to perform this task are deployed elsewhere, where they are also urgently needed,” says Onur Yavuz. “This has significantly increased motivation and satisfaction.”

Technical Manager Uwe Friedl, who has been an integral part of Nagel-Group for more than 25 years, also has nothing but praise for the Cobot and Smart Robotics. “The installation and commissioning went without a hitch,” he summarizes. The Smart Palletizer was up and running in just three hours. Unlike an industrial robot, it does not require an enclosure, which significantly speeds up set-up and enables mobile use at various locations in the company. This is not a disadvantage in terms of safety – in the event of accidental contact with a person, the cobot stops immediately to prevent accidents.

Successful implementation, impressive results

Of course, there were also challenges at the beginning of the test phase: An incorrectly placed cardboard box could generate errors, causing the robot to pause its work. However, these problems were quickly resolved through training and adjustments to the programming. “The customer support and communication from Smart Robotics were also exemplary at all times,” praises Friedl. “We learned from this process and the results today are impressive.” From November 2023 to February 2024, the robot was used for end-of-line palletizing as part of the test phase. During this time, it palletized 250,000 cartons on 5,500 pallets and impressed with an availability rate of 97.5%.

The success in Emleben is just the beginning. The Nagel-Group is planning to expand the use of cobots. Following the successful test phase, the permanent purchase of two palletizing robots was agreed. “In my view, we have successfully improved work ergonomics and efficiency with the Smart Palletizer,” sums up Uwe Friedl. “It is a flagship for the modernization of our site.”

Site Manager Torsten Lämmerhirt also welcomes the automation measure. “In view of current and future developments on the labor market, it is a necessary survival strategy for companies with personnel-intensive processes to intensify the automation of workflows,” he explains. From his perspective, this is not just a matter of economic necessity. “Implementing automated processes also makes the company more attractive to potential employees.” The introduction of the palletizing robot at Nagel-Group in Emleben is therefore a good example of how innovative solutions can not only improve efficiency and quality, but also increase employee satisfaction. “Here, man and machine work hand in hand to achieve great things together,” concludes Onur Yavuz.

f.l.t.r. Onur Yavuz, Project Manager in the Value Added Services division and Uwe Friedl, Technical Operations Manager (both Nagel-Group)