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Brownfield palletizing system with maximum flexibility

Modernization of an almost 30-year-old palletizing and conveying system during operation

Customer
Packaging manufacturer

Year
2025

The highlights at a glance
Elimination of semi-finished products and tools, independence from geometry and volume thanks to low fixed costs and optimized warehousing, digital process chain with fast response times and short distribution channels, „just-in-sequence“ finishing“
Replacement of an almost 30-year-old system in 24/7 operation
Highly dynamic robotics with increased overall output
Flexible assignment of production lines to palletizing stations via Sushiband
Integration of several purchased trades into an overall system
Future-proof scalability thanks to prepared robotic expansion
The project
The challenge

The existing palletizing and Container conveyor technology was technically outdated after almost three decades of use. Spare parts were no longer available and the intralogistics could no longer meet the increasing demands for precision, speed and flexibility. The goal: The modernized system seamlessly into the existing infrastructure to integrated without interrupting 24/7 operation. 

The solution

fpt robotics developed a customized palletizing and conveyor technology solution with highly dynamic robotics and increased overall output. In addition to the complete integration of new systems such as Pallet conveyor technology, The existing conveyors have been taken over and integrated into the new conveyor system, cross transfer carriage, vertical conveyor and gluing line. A central element is the Sushiband, which allows an individual assignment of each production line to each Palletizing station enables - scalable for future Robotic extensions. 

As part of a replacement investment, the VG Nicolaus GmbH a modern palletizing solution that combines existing pack conveyor technology and pallet conveyor technology with new, high-performance components.
The particular challenge lay in the integration during ongoing production operations. A continuous material flow was achieved through the targeted use of cross transfer carriages, vertical conveyors and a gluing line.
The „sushi belt“ behind the palletizing system ensures that products can be transported flexibly from all production machines to all robots. Future scaling via additional robots was already taken into account during the planning phase. The result: a future-proof intralogistics solution that combines precision, speed and flexibility - in a demanding brownfield environment. 

Contact us

Contact us

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Give us a call, write to us or make an appointment directly for a non-binding initial consultation. We look forward to your challenges!

Portrait Heiko Wenzel fpt robotics
Heiko Wenzel
Head of Robotics & Intralogistics Division
+49 (7520) 9513 - 0
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