Bag singulation with automatic material change

The customer was faced with the task of automating a previously manual singulation process. The goal was to reduce personnel costs, increase process reliability, and minimize potential sources of error in the production workflow. In the manual process, for example, bags could be forgotten, loaded in the wrong version, or loaded in an incorrect quantity.

A particular challenge lay in the broad product spectrum: different pouch variants with varying weights and properties had to be separated reliably and reproducibly. At the same time, the required cycle time had to be maintained at all times despite the high product variety. The solution therefore had to combine maximum flexibility with high process stability and performance.

FPT Robotics implemented a fully automated singulation solution that processes a wide variety of bag types reliably, quickly, and process-safely. The singulation is carried out using vacuum technology, enabling the products to be picked up precisely and fed into the subsequent process.

To efficiently handle the high product variety, an intelligent conveyor loop with a sushi belt was integrated. Based on the product identification number, automated material changes take place so that the required bags are provided without manual intervention. Six material buffers ensure a continuous supply to the system and support uninterrupted operation.

A major milestone in the project was the decision in favor of an automatic nozzle change with an integrated changing station. As a result, the system can flexibly process different pouch sizes and properties while simultaneously offering the customer the necessary future-proofing for additional product variants. For precise product removal, a camera system determines the exact pick position of the pouches. Subsequently, each product is checked using a scale to ensure quality and completeness. Following successful inspection, the output and transfer to subsequent process steps takes place automatically via a chute that connects the pouch singulation cell with the downstream conveyor technology.

The result is a flexible and future-proof automation solution that ensures high process stability, eliminates sources of error, and reliably achieves the required cycle performance.