Apple producer uses robotic packer

Adrian Scripps is Tesco’s largest apple supplier. In 2018, the firm took the decision to invest in two fully automated packing and palletising lines and upgrade the end-of-line kit on two existing lines, following an investment in new flow wrapping equipment. Its existing mechanical layer crate packing systems were limiting output, as they could not keep pace with the flow wrappers. 

“Our existing packing system was working flat out at 15 cycles per minute; we soon worked out that we could put apples into the flow wrapper much quicker than this,” recalls Adrian Scripps MD James Simpson.

The company considered other packing systems, but it was the inherent flexibility of the award-winning UniPAKer robotic crate packing solution that convinced Adrian Scripps to partner Brillopak on this project.

“We looked at mechanical systems where the pack is turned to orientate it, but the flexibility of the UniPAKer won us over – it is infinitely programmable and allows you to make very small adjustments to get the pack to the exact target location,” explains James. 

Each of the four UniPAKer crate loading cells at Adrian Scripps houses two delta type robots, each performing a single pick. The benefit of a single pick is that it eliminates the need for accumulation. To maximise packing speed, the crate is dynamically loaded as it is moving;  working alongside each other, the robots take it in turn to partially fill the crate, picking individual packs off the infeed conveyor and positioning them deftly and precisely in the crate at the programmed orientation. The robots perform this task with a degree of dexterity and rotation that would not be feasible with a layer-based automated handling system.

Many robotics suppliers shy away from applications involving delicate fruit such as apples, as they bruise very easily. The speeds required to achieve target paybacks cannot be met without unacceptable levels of product damage, rendering some automation projects unfeasible.

Brillopak overcomes these challenges through innovative end-effector design and unrivalled experience of motion control. 

“Apples are very delicate products, making them very difficult to pack at high speed. We are the only automation supplier who can successfully pack apples at speeds of 75 ppm, without damaging the product. We have achieved this via innovative end-effector design, combined with our knowledge of motion control and robotics,” explains Brillopak director David Jahn.

One of the hotspots for damage is the point at which the pack is released from the end-effector, with some rival robots dropping fruit from heights of 250mm. Brillopak has developed a robot control system that has allowed it to optimise the acceleration/deceleration curve by enabling greater adjustability of parameters.

“When lifting a pack of apples, the robot arm accelerates strongly upwards into a curve, then decelerates down into the crate, so the pack is tightly controlled as it reaches the bottom of the crate.” explains David.

The project saw Brillopak install four UniPAKer robotic crate packing systems, four Crate DESTAKers, four vertical accumulation units and three robotic palletisers.

For more information, visit www.brillopak.co.uk