Automated Feeding of Packaging Material – Flexible Robotics Solution for Efficient Small Parts Packaging

For the customer, Würth Industrie Service GmbH & Co. KG, SPIE developed an automated solution for feeding packaging materials for small parts. At the core of the system is a carton erector combined with two collaborative robots (UR20 and UR7e), which together handle the depalletizing of KLT containers as well as the erecting and provision of cartons. The system is complemented by a camera-based position detection system to ensure correct alignment of the packaging units. The system is directly connected to an existing weighing machine and can be flexibly transferred to comparable machines.

Challenge and Objective

The customer’s starting situation was characterized by a high level of manual effort. Packaging materials such as cartons and KLT containers of various sizes had to be manually provided to the weighing machine. This process was time-consuming and monotonous. The goal of the project was to develop a flexible, automated solution that reliably feeds different packaging types, keeps pace with the cycle time of the existing weighing machine, and enables the longest possible autonomous runtime. In addition, the system was to be designed to be mobile, so that it could be used on multiple, similarly structured machines.

Solution

The implementation was carried out in close coordination with the customer. The starting point was a rough concept that addressed the specific challenges on site — in particular the limited space and the complexity of the wide variety of packaging.

In the next step, a feasibility test (proof of concept) was carried out. Various carton types were successfully erected automatically, and the correct handling of different KLT containers was validated.

In parallel, a flexible gripper system was developed and tested, capable of picking up both cartons and KLTs using vacuum technology. Position detection of the different container types was implemented via a camera-based system. Following successful validation, the actual project phase began.

First, the mechanical design of the steel frame was developed, making optimal use of the limited installation space through a split layout and integration into the existing machine. In parallel, electrical engineering planning as well as the programming and integration of the two UR robots, including end effectors, took place. The UR20 robot handles the depalletizing and provision of the packaging materials, while the UR7e robot erects the cartons and prepares them for the further process. This interaction ensured the weighing machine’s required cycle time could be reliably maintained.

After procuring all components, assembly took place at the Oberwang site. Following successful acceptance by the customer, the system was installed and commissioned on site. Particular challenges in the project included the limited space, maintaining cycle times, the variety of packaging types, and the development of a gripper that was both lightweight and robust. Switching between cartons and KLT containers is done manually. To ensure a high autonomous runtime of around 30 minutes, special feed carts were developed that stock sufficient material. At the same time, the system was designed so that autonomous mobile robots (AMRs) could take over material feeding in the future.

Benefits

With the implemented solution, the manual and repetitive material feeding process could be fully automated. This relieves employees and increases the efficiency of the entire packaging line. Once the feed carts are loaded, the system operates autonomously over an extended period and can be flexibly deployed on different machines. The intelligent combination of robotics, camera system, and custom-designed mechanics ensures a reliable and process-safe provision of a wide variety of packaging types.

In addition, a future-proof foundation was created at Würth Industrie Service GmbH & Co. KG, enabling further automation — for example, through the integration of AMR systems.

These SPIE strengths were put to use

About the customer

Würth Industrie Service GmbH & Co. KG is an internationally active company of the Würth Group, headquartered in Bad Mergentheim. It specializes in supplying industrial customers with assembly and fastening materials, as well as procurement and logistics solutions in C-parts management. With automated logistics systems, the company supplies customers worldwide and ranks among the leading partners for industrial supply solutions.

Industry
Industrial trade
(assembly and fastening technology)

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“Our goal was to sustainably automate a time-consuming, manual packaging process. SPIE understood our requirements and worked with us to develop a flexible, practical solution. From the very beginning, the collaboration was partnership-based, transparent, and solution-oriented. Today, we benefit from greater process reliability, increased efficiency, and a noticeable relief for our employees. The system also creates a solid foundation for further automation steps. We would be happy to carry out future projects with SPIE as well.”