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Robots replace manual palletizing at Sargento Foods

A complex system comprising eight robotic palletizing cells with three lanes each replaces manual palletizing operations at Sargento’s Plymouth, WI, plant.

Robots palletizing cases of cheese have been decorated by Sargento with Swiss-hole decals to ‘cheesify’ them.
Robots palletizing cases of cheese have been decorated by Sargento with Swiss-hole decals to ‘cheesify’ them.

Sargento Foods Inc. has been running a centralized palletizing system at its plant in Plymouth, WI, for almost two years. Installed in phases with completion in 2014, the system was implemented to replace manual palletizing on multiple production lines producing sliced, snack, and shredded natural cheese products. Although primarily handling products for the retail market, the system also supports foodservice and industrial customers as well as some club-store applications.

Due to space limitations within the facility, the centralized palletizing concept was the most practical option. Requirements for the system included a neutral to positive return on cost of goods sold, a reduction in the forklift traffic around the production lines, improvements in the quality of work, especially ergonomics, and the installation of a robust and reliable system.

After competitive analysis, which included a number of qualified vendors, Sargento selected Intelligrated Systems to design and implement the system. According to Barry Blatz, Sargento Senior Project Engineer for the project, Intelligrated offered the best combination of self-manufactured conveyor components, Fanuc robotics, large-system experience, and in-house controls integration.

During operation of the system, after cases are filled with product on each production line, they are sealed and labeled with a 128-style UPC code. They are then carried away from the production line by elevated conveyors to an overhead level and introduced to high-speed trunk-line conveyors. These conveyors further combine cases into a single file as they travel—up to to 700 feet, in some cases—to the central palletizing area.

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