Michael Cothran
North Central Sales Manager
BluePrint Automation (BPA)
1. How do you evaluate when to use cobots vs. a robotic system? What criteria should you consider such as speed of the operation, product variety, number of SKUs, initial investment, floorspace, etc.?
Historically, BPA has only supplied larger robotic systems. Our systems are geared towards high-rate secondary packaging loading or high sanitation direct-contact food manipulation. Cobots aren’t geared towards these types of tasks. Where they strive is in their simplicity and confined workspace. Tasks where the cobots are going to be working in close quarters with humans or situations where the robot needs to be mobile and move from line to line are best suited to cobots. Small-scale palletizing is a great application for these units.
2. What tasks are better suited for cobots than for other types of robotics? What are the strengths and limitations of cobots?
The biggest strengths of cobots are their smaller footprints and relative ease of programming. Cobots do not need a ton of space to operate, and they can be set up to run in close proximity to personnel (at reduced speeds of course). The most obvious place to use cobots is in palletizing cells, where the case weight and speed are not enormous. The biggest limits of these systems are the weight restrictions and speed restrictions of the cobots. Usually, to reach taller pallets or applications, the robots need to be mounted on a large pedestal or even need to be able actuate up and down as needed. This eats into their cost and space efficiencies.
3. What are the main limitations when it comes to robotics in packaging? What tasks such as variety packs, placement of delicate products, bulk products, etc., cause the biggest challenges and where have they improved the most in recent years?
The biggest limitation of robots is the balance between reach and speed. Delta robots are wicked fast, capable of cycling at 100 picks/min in certain circumstances. Reach can be a challenge with these robots though, so deeper RSC cases can be difficult to fit within a delta robot’s picking window. Six-axis robots can solve this reach challenge, but they do not cycle at nearly the rate of the deltas. This means your cycles need to be more efficient (picking multiple products at a time) or more robots will be required. Systems designed around bulk products and variety packs, like our BPA bulk product feeder have made big strides in the last decade, especially as variety packs continue to grow in popularity. These systems work well, but they do require a large amount of footprint to operate. Technology around more hand-like grippers continues to improve as well, which will allow delicate products to be picked more reliably and quicker.
4. What are the limitations and advantages of robotics in food production?
The biggest limitations of robotics are perhaps the footprint and initial investment. Depending on the complexity of a given application, robots might have trouble fitting in an allotted space. This is why BPA has developed its robot frames to house all controls and electronics to help us fit in as many places as possible. Likewise, the initial investment of a robotic system can be a tough pill for some companies to swallow. However, the beauty of a robotic system is, once it’s in place, it shows up to work every day! Robotics help cut down on the menial and repetitive tasks that lead to high staff turnover because of the poor ergonomics and boredom. The modularity of robotic systems means you can add capacity in the future as well.
5. How can processors and co-packers more easily maintain their robotics, especially with today’s skilled labor shortage? What sort of options are available for processors and co-packers such as robotics as a service (RaaS) program?
BPA offers onsite training through our aftermarket and service group. We tailor materials specific to a project and offer to teach in a classroom type setting. We try to give us much onsite/on the job training as possible during start-up as well. Similarly, many robot vendors (like our partner ABB), offer training seminars at frequent intervals that many companies take advantage of. Outside of training, we offer our ARHP (Asset Health Reliability Program) where at intervals specified by the end-user, we return onsite to tune, train, and assess the state of our supplied equipment. This helps cover any holes in a maintenance program and helps to break any unwanted habits that are developing. Robots as a service (RaaS) is a trend that seems to be gaining traction. The RaaS companies will own and maintain the equipment and end-users essentially “hire” the robots for a set duration at an hourly rate. This is a unique way to dive into robotics without investing a ton of upfront capital or having an extremely skilled staff.