CKF Systems, a supplier of automated handling, robotic solutions and conveyor systems, has developed a range of robot handling cells to help businesses that are unprepared for the complexities of automation.

The AC25, a direct replacement for existing manual operations, is said to be easy to install and operate. At a cost of £80,000, CKF Systems says the system will typically provide a payback in under two years.

“Our objective was to design a low cost robot palletising cell that can be installed as a standalone operation or combined for multiple feeds with a common discharge into secondary palletising operations such as spiral wrappers or pallet stacking,” explains Kevin Staines, sales director at CKF Systems.

“All aspects of the cell are based on proven technologies and utilise user friendly interfaces for both operatives and engineers. The operational simplicity of this palletising cell means that we have addressed one of the biggest concerns of those SME’s still resistant to change; that their businesses are unprepared for the complexities of automation.”

A typical manual palletising line is, by its very nature, a labour intensive handling operation with inherent limitations in respect of box sizes, weight and restricted flow rates.

The AC25 will operate at 15 cases per minute and, unlike a human operative, is not compromised by the introduction of layer cards or heavy boxes, according to the company.

In addition, current legislation restricts the maximum unit weight that an operative can lift and also defines the maximum achievable stack height on a pallet. However, the AC25 robot palletising cell includes increased stack heights that provide better trailer utilisation, reducing transportation costs and therefore providing a subsequent environmental benefit.

Manufactured in the UK, the cell uses an ABB 4-axis robot and industry standard equipment and comes with full support, including training and spares, a 12-month warranty and the option for a range of add-on features. It is capable of handling cases with dimensions of up 400mm long x 300mm wide x 250mm high and a net weight of 25kg. It is designed with enhanced handling capabilities and high reliability levels.

The CKF palletising cell will handle euro or UK pallets with layer cards as an option. In addition, the cell can be expanded to accommodate a series of additional modules, such as vision cameras, layer cards, open-flap detection and pre-collation of boxes for increased throughputs and alternating pallet patterns.

Mike Wilson, chairman of the British Automation and Robot Association (BARA), noted, “The pressures on operating costs and output levels and the difficulty of attracting people for arduous tasks are real threats to the long term sustainability of businesses that do not embrace automation.”

He added that CKF’s AC25 is a cost effective solution that can significantly improve the overall efficiency and flexibility of a business. “The cell works in a small footprint and removes all issues related to human interface such as repetitive strain problems, rest breaks and availability of labour,” Wilson explained.