Enhancing Packaging Ergonomics with Collaborative Robotics in Pharmaceutical Production

As a leading manufacturer of natural and herbal pharmaceuticals and cosmetics, Phytopharm Klęka S.A. operates a demanding three-shift production schedule. Within its packaging department, operators faced the physically taxing tasks of handling variable bottle stacks, navigating uneven pallet surfaces, and lifting heavy cartons of finished products.

These manual processes increased the risk of accidental injuries and contributed to workplace monotony. The company sought an automated solution to improve ergonomics and reduce operator fatigue. A key objective was to secure greater operational flexibility to seamlessly manage staff absences and ensure reliable production output without sacrificing throughput efficiency.

Automating the Packaging Line
To address these operational bottlenecks, system integrator ZW Automation implemented a robotic solution featuring two collaborative robots (cobots) from the FANUC CRX series. The automation strategy was deployed at both the beginning and the end of the company's Romaco packaging line.

At the start of the line, a FANUC CRX-20iA/L cobot with a 20 kg payload and 1,418 mm reach manages the complex depalletizing process. To handle the variable stack heights and delicate packaging surfaces, the cobot is equipped with a custom vacuum gripper featuring soft suction cups and an integrated vacuum control system. This ensures stable, precise, and smooth product handling without causing any damage.

At the end of the line, a FANUC CRX-25iA cobot is tasked with stacking heavy boxes of finished products. Boasting a payload capacity of up to 30 kg and an extended reach, this unit efficiently builds pallets up to 1.6 meters high. To guarantee safe human-robot collaboration, the palletizing cell is protected by a trio of safety scanners. This setup eliminates the need for complex peripheral equipment or physical fencing, preserving an open and accessible workspace.

Software Integration for Independent Pattern Management
A crucial component of the end-of-line automation is the integration of FANUC's PalletTool^® software. This specialized program simplifies the simulation and management of palletizing operations.

The software empowers machine operators to independently generate optimal stacking patterns and configure protective slip sheets directly through an intuitive interface. By enabling rapid and flexible carton format changeovers without the need to modify the cobot's core programming, the facility significantly increased its adaptability to changing production demands.

Exceeding Performance Targets and Enhancing Safety
The dual-cobot installation has transformed the packaging workflow, delivering efficient, precise, and flexible handling that surpassed initial performance estimates. The depalletizing station reliably achieves a throughput of 3.4 packs per minute, while the end-of-line system stacks 8 cartons per minute.

"In today's world, where knowledge and expertise have real value, we looked for robotic solutions that would support our employees in simple activities," explains Bartosz Wojtecki, Pharmaceutical Production and Warehouse Manager at Phytopharm Klęka. Project Manager Bartosz Kwiatkowski notes that the targeted automation successfully minimized injury risks and reduced job monotony without compromising production efficiency. Ultimately, the collaborative workstations support intuitive operation and flexible labor scheduling across the facility's rigorous three-shift cycle.

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

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