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14 Oct 2021

BRILLOPAK’S UNIPAKER REDUCES LABOUR, ENERGY AND WASTE CONCERNS FOR FOOD PRODUCERS

Brillopak Stand: 704
Brillopak’s UniPAKer, for perfect product placement of fresh produce, meat/fish packs and ready meals into crates

At this year’s Robotics and Automation Show, Brillopak will highlight the benefits of its newest award-winning and affordable UniPAKer robotic crate packing platform, designed to protect food manufacturers against rising energy costs and the current labour shortage while boosting their sustainability credentials.

With the NFU reporting an estimated 500,000 vacancies in the food and drink sector[1], automating repetitive and physically demanding end-of-line tasks, such as picking, packing and palletising, can help food producers to safeguard their business during the current labour crisis. Brillopak’s recently upgraded single head-dual pick robotic crate packing cell- the UniPAKer - strikes the optimum balance of fast acceleration and gentle pick and placement, making it ideal for automatically crate loading perishable products, including meat, fish, ready meals and fresh produce.

 

Easing recruitment pressures

“The benefits of replacing manual workers with robots are widely known – increased efficiency, consistent output and a rise in productivity, to name a few,” says David Jahn, Director of Brillopak. “But with manufacturing in general and the food sector in particular in the grip of a severe labour shortage that has been exacerbated by Covid and Brexit, more producers than ever before are turning to automated solutions such as the UniPAKer to fulfil orders and maintain throughput. We are excited to demonstrate the benefits of our redesigned system – which now boasts a 10% reduced footprint – to visitors to Robotics & Automation; especially those who are struggling to fill vacancies.”

The UniPAKer is highly efficient at picking up and moving up to 120 chilled or fresh product packs per minute dependent on machine model. For example, two selection dips or two family-sized convenience meals can be packed on a small footprint single cell UniPAKer at 70 packs a minute. It ensures consistent lifting capacity when picking, and gently placing packs of various weights, sizes and packaging types into retail crates.

Cutting energy costs

In addition to mitigating against the current labour crisis, the next-generation UniPAKer offers a 45% reduction in compressed air consumption, also helping food producers to lower their energy bills. Never has this been more necessary; energy costs are forecast to rise by as much as 30% in 2022[2] and compressed air typically accounts for up to 40% of a manufacturing facility’s total energy bill, with leak rates exceeding 50% on some systems.

Other energy-saving improvements include: the universal deployment of servo motors (replacing pneumatics) that only require power when operational; reducing the weight of the end-effectors and other moving parts to decrease power requirement; and employing energy-efficient three-phase conveyor motors.

“Our focus on sustainability has reduced the UniPAKer’s power consumption by 10% compared to previous models in the series,” confirms David. “Not only that, but it has also improved its performance, as the lighter, smaller end-effectors result in a faster pick speed while retaining presentation.”

Reducing food waste

Continuing with the theme of sustainability, the upgraded UniPAKer’s gentle handling helps to address one of the biggest avoidable waste hotspots in food production and distribution: split top-seal packaging and torn film lids. “On high-speed side or drop loading automated production lines, one broken seal has the potential to tip and cross-contaminate an entire tray,” acknowledges David. “Aiming to address this, the UniPAKer’s gentle handling makes it ideal for materials traditionally prone to piercing, including thin films, pillow bags, resealable packs and newer, more sustainable packaging substrates, helping to reduce food waste during the packaging stage.”  

As UK food producers navigate their way through the post-Covid landscape amid rising energy bills, the climate crisis, and the current labour shortage, Brillopak’s robotic crate loading solution is uniquely placed to mitigate against all three issues. “We look forward to explaining to visitors at Robotics and Automation how the UniPAKer can increase food producers’ resilience in the face of today’s unprecedented manufacturing challenges,” says David.

 

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