EDIH4Marche, in collaboration with i-Labs Industry, has pursued an ambitious automation and innovation project for Altesia, a small and medium-sized enterprise (SME) based in Marche, Italy, specializing in implementing solutions for food companies. This project, featured among the success stories of the European Digital Innovation Hubs network, focused on a feasibility study for a collaborative robotic palletization system to optimize efficiency, safety, and product quality in end-of-line operations.
An Added Value: The Test Before Invest Service by EDIH4Marche
Altesia benefited from the Test Before Invest service offered by EDIH4Marche, a crucial initiative to help companies evaluate and experiment with innovative technologies before making a full investment. This service allows businesses to reduce investment risks by offering a preliminary testing phase in controlled environments such as i-Labs Industry’s laboratories. For Altesia, Test Before Invest was essential for optimizing technological choices and designing a tailored automation system, verifying every aspect in advance to ensure the system met specific production needs.
Challenges Addressed
The project aimed to assess the feasibility of automating the end-of-line palletization process while meeting stringent requirements. Key challenges included the need to develop a system capable of:
- Supporting two palletization modes (tight and wide sequence);
- Simultaneously palletizing four pallets;
- Handling boxes of varying sizes and weights;
- Operating in a limited space while maintaining high production cycles (400 boxes/hour);
- Employing collaborative robots to avoid safety barriers.
Technological Solutions Implemented
To meet these requirements, the FANUC CR-35iB collaborative robot was selected, equipped with a Schunk PHL-40 pneumatic gripper specifically designed to handle boxes without causing damage. The gripper uses rubber layers to enhance grip strength without compromising the boxes’ integrity. Simulations using Roboguide software demonstrated that the robot could palletize up to 480 boxes per hour, exceeding manual handling capabilities.
Tests conducted in i-Labs Industry’s laboratories confirmed the solution’s effectiveness, proving that the robotic system could operate efficiently within spatial constraints and with the flexibility required to adapt to future production demands.
Results and Benefits for Altesia
The implemented solution delivered significant advantages for Altesia:
- Increased Efficiency and Productivity: With a capacity of 480 boxes/hour, the system reduces bottlenecks and enhances productivity, enabling Altesia to respond more rapidly to market demand.
- Labor Cost Reduction: Automation frees workers from repetitive tasks, allowing them to focus on higher-value activities such as quality control and process optimization.
- Improved Safety: Collaborative robotics minimizes the need for manual heavy lifting, reducing injury risks and creating a safer work environment.
- Guaranteed Product Quality: The advanced gripper ensures gentle handling, minimizing product damage during palletization.
- Flexibility and Scalability: The robotic system is designed to adapt to future configuration changes, providing Altesia with a competitive edge and the ability to efficiently scale production capacity.
Social and Economic Impact
The introduction of a robotic palletization system offers significant social and economic benefits:
- Enhanced Competitiveness: Automation positions Altesia as a leader in the industry, improving its competitiveness and potentially attracting new clients.
- Process Optimization: Robotic palletizers accelerate operations, reduce downtime, and optimize overall workflow thanks to their ability to operate continuously.
- Operational Cost Savings: The robotic system reduces the need for labor in physically demanding tasks, lowering labor costs and increasing profitability.
Opportunities for SMEs in Marche
The solution developed with Altesia demonstrates that robotic automation is a viable choice for companies seeking to enhance efficiency, safety, and quality. EDIH4Marche and i-Labs Industry will continue to support local SMEs in their digital transition, offering innovative technologies to boost competitiveness and sustainability.
Special Thanks
EDIH4Marche extends its gratitude to Fabrizio Stella, CEO of Altesia, for the trust and collaboration demonstrated throughout the project. His commitment and vision were essential to the success of this initiative.
This success story highlights EDIH4Marche’s dedication to promoting digital transformation and supporting businesses in achieving economic growth and adopting scalable, cutting-edge solutions.
