Cobot palletizing improves dairy packaging efficiency

Dairy processor Privatmolkerei Bauer GmbH & Co. KG, based in Bavaria, produces yogurt, drinking yogurt and cheese products distributed nationwide. Operating in a competitive market, the company continuously develops new product formats while optimizing production and packaging processes to maintain quality and improve operational efficiency.

A key objective has been to automate physically demanding manual tasks while ensuring consistent product handling. In the packaging line, the final palletizing step—stacking trays of pouch-packaged yogurt onto euro pallets—was previously performed manually. This created constraints in process reliability and ergonomics, prompting the search for an automated solution.

Technical challenge
The automation of end-of-line palletizing introduced several constraints. The system needed to handle at least three trays per minute while operating within limited floor space, without protective fencing. Additionally, the trays used were open-topped, containing multiple individual packages that had to remain stable during handling. The process also required the automatic insertion of cardboard interlayers between pallet layers.

According to Anton Weber, project manager at Privatmolkerei Bauer, “the primary goal was to increase process reliability, while ensuring the solution could be easily integrated and operated within existing production conditions.”

Solution selection and deployment
Following a structured evaluation, Privatmolkerei Bauer selected a solution developed by Profipack Verpackungsmaschinen GmbH, a specialist in packaging and intralogistics systems. The company’s experience in food and beverage applications, combined with its proximity to the production site, supported efficient project implementation.

To meet the requirement for open and accessible operation, Profipack implemented a collaborative robot-based system for the first time in its portfolio. The cobot performs multiple tasks: removing trays from the upstream packer, placing them onto pallets, automatically switching between pallet positions, and inserting intermediate cardboard layers.

The system was designed to accommodate different pouch formats and can be adapted through programmable configurations, ensuring flexibility for future product variations.

Robotic technology integration
The solution is based on a six-axis collaborative robot from Yaskawa. The selected model combines a payload of 20 kg with a wide working range, enabling efficient handling of multiple trays per cycle.

A key component is a modular lightweight vacuum gripper developed by Profipack, capable of handling two trays simultaneously. This design increases throughput while stabilizing the load, particularly important for open trays. A slight inclination of the gripper enhances grip security during transfer.

The robot integrates cabling and media supply within its structure, improving hygiene and reducing interference. Programming is simplified through manual guidance features, supporting efficient setup and operation. The human-robot collaboration concept, implemented with support from Yaskawa, ensures safe operation without additional protective barriers.

Operational results
The palletizing system has been in operation since early 2026 and is integrated into the existing packaging line. It achieves a cycle time of approximately 20 seconds per tray while maintaining stable and repeatable performance.
The automation of palletizing has reduced manual handling requirements and improved process consistency. The ability to operate without safety fencing allows efficient use of available space, while flexible programming enables adaptation to different product formats.

Anton Weber states: “The system operates safely and in a space-saving manner without additional protective devices. It has demonstrated robustness and reliability under continuous three-shift operation.”




Perspectives
The project demonstrates how collaborative robotics can be applied in food processing environments to automate end-of-line operations while maintaining flexibility and safety. The successful implementation has established a foundation for further automation initiatives at Privatmolkerei Bauer, particularly in areas combining ergonomic improvement with process optimization.

Edited by Maria Brueva, Induportals editor – adapted by AI.

www.yaskawa.eu.com