Automating Carton Magazine Loading for Packaging Lines

Application areas: Carton packaging automation, machine tending, material handling
Industry sectors: Food and beverage, packaging, consumer goods manufacturing

Manufacturers of coffee, pasta, cheese, cosmetics, pet food and other consumer goods rely on secondary packaging systems to prepare products for transport and retail distribution. SOMIC Verpackungsmaschinen GmbH & Co. KG develops automated packaging systems that place primary-packaged products into shipping cartons and shelf-ready packaging for a wide range of industries.

As production volumes increased, the company identified manual loading of carton blanks into packaging machines as a process that limited productivity and created unnecessary physical strain for operators. SOMIC therefore developed an automated solution to improve material flow while reducing repetitive manual handling.

Manual loading created operational constraints
Loading carton magazines traditionally requires operators to repeatedly transfer stacks of carton blanks into the machine. Besides being physically demanding, the task interrupts production whenever replenishment is required and ties personnel to low-value activities.

SOMIC's development team sought an automated solution capable of supplying cartons continuously throughout production while maintaining reliable operation across different carton formats and packaging configurations. The objective was to improve process stability, increase machine availability, reduce manual intervention and enable operators to concentrate on monitoring and production supervision.

Collaborative robot automates carton supply
The resulting solution, SOMIC CoboLoad, automates the loading of carton magazines using a collaborative robot integrated directly into the packaging system.

At the centre of the system is Yaskawa's HC20DTP collaborative robot equipped with a dedicated SOMIC gripper. Depending on the carton geometry, the robot can use either an internal or external gripping system. A quick-change tooling mechanism allows rapid adaptation to different carton formats commonly processed on the same packaging machine.

The system combines robotics with 3D vision and sensor-assisted gripping technology. Image processing automatically identifies the position of carton stacks, while sensors guide precise gripping and placement inside the magazine. Stack misalignment and inclination are automatically compensated, intermediate layers can be removed using vacuum suction cups, and an optional turning station adjusts carton orientation when required before loading.

This combination enables reliable automated handling even when pallet stacks are not perfectly aligned.


Safe integration into existing production lines
Because the robot operates close to production personnel, SOMIC required a solution suitable for human-robot collaboration while maintaining industrial performance.

The HC20DTP collaborative robot met these requirements through certified safety functions, integrated cable routing and collaborative operation without requiring permanent protective fencing during safeguarded operation. Additional protective devices such as light barriers or safety mats can be incorporated for higher-speed applications.

Another selection criterion was the robot's operating range. Its reach of 1,900 mm allows access to every position on a standard Euro pallet, eliminating the need for pallet repositioning during automatic loading. With a payload capacity of up to 20 kg, repeatability of 0.05 mm and IP67 protection, the robot combines industrial robustness with collaborative operation.

Project Manager Brigitte Stockenreiter explained the selection: "The HC20DTP is a fully fledged industrial robot with high power and speed that can also operate as a collaborative robot. This allows it to be integrated into existing production environments without extensive safety fencing while maintaining the flexibility required for different applications."

PLC integration simplified operation
Beyond robotic performance, SOMIC required complete integration into its existing machine control architecture.

Using Yaskawa's MotoLogix software interface, the robot is programmed and controlled directly through the packaging machine's PLC using the IEC 61131 environment. Motion control calculations continue to be handled by the robot controller while operators work entirely within the familiar SOMIC control interface.

The solution also enables integration into larger production lines through OPC UA while preserving a consistent operator interface. According to SOMIC, customers can operate the robot through the same HMI used for the rest of the packaging machine, reducing training requirements and simplifying commissioning.

Improved production continuity and operator ergonomics
The automated loading system delivers continuous carton supply across an entire pallet without operator intervention, supporting uninterrupted packaging operations over extended production periods, including night shifts.

According to SOMIC, the implementation provides higher packaging line availability, more consistent carton feeding, improved operator ergonomics, lower manual labour requirements and reduced personnel costs. Automation also allows operators to shift from repetitive loading tasks to production monitoring and other value-added activities.

The solution was presented at Interpack 2026, held from 7 to 13 May 2026 in Düsseldorf, Germany, where initial customer projects were already under preparation following its introduction.

Edited by Sucithra Mani, Induportals editor – adapted by AI.

www.yaskawa.com