Case

Mobile robots and palletizing systems for SKY-LIGHT

Back to cases

Production logistics and palletizing

Automated internal logistics with mobile robots and a palletizer

SKY-LIGHT A/S has worked with optimization and automation for many years and installed its first AGV in 2006. As a continuation of optimizing flow and the working environment, SKY-LIGHT wanted to automate internal logistics related to the handling of empty and full cardboard boxes, as well as palletizing.

The goal was to increase capacity, reduce manual handling, and ensure a stable, future-proof solution for production, based on overall requirements:

  • Automated transport of empty and full boxes

  • Capacity of approx. 190 boxes per hour

  • At least 15 wrapped pallets per hour

  • Flexible and safe solution with expansion options

  • Stable operation with high uptime and a focus on operator safety

Mobile robots and fully automated palletizing increase capacity and reduce manual handling

CESTEK delivered a complete internal logistics solution based on AMR mobile robots, automated box conveyors, and a fully automated palletizer with an XYZ gantry and vacuum tool.
The solution connects case erectors, production machines, the palletizer, and wrapping in one coherent, automated process.

Empty boxes are automatically transported from the case erectors to the individual machines, while full boxes are collected and taken to the palletizer. Here, the boxes are closed and automatically palletized in customer-specific patterns. The finished pallets are then conveyed to wrapping and prepared for pickup by AGV or forklift.

The integrated mobile robot solution uses OMRON LD60 fitted with CESTEK’s Spacer and Top Conveyor, which efficiently transfers boxes between conveyors.

The system is controlled via separate PLC and HMI solutions for the robots, palletizer, and wrapping machine, while a central fleet manager ensures optimal utilization of the robots and automatic charging.
Solution type:
  • Mobile robot solution (AMR)
  • Automated palletizing with gantry
  • Integrated internal logistics and control
Key components / products:
  • 4 pcs. Omron LD60 mobile robots with CESTEK top conveyor
  • Box conveyors at machines and case erectors
  • Palletizer with XYZ gantry and vacuum tool
  • Transfer cart and pallet magazine
  • Automatic wrapping machine
  • PLC, HMI, and fleet manager control
  • Integration to 2 pcs. Global AGV, as well as traffic control of these
Partners:
  • Omron (mobile robots)
  • Q-System (pallet handling)
  • Ubro Vangby (pallet wrapper)

Results and benefits:

The implementation of the solution has had a clear positive impact on both production and the working environment at SKY-LIGHT. Several previously manual and physically demanding processes have now been automated, while handling costs have been reduced.

Increased efficiency
  • Automated transport reduces waiting time and bottlenecks
  • Stable palletizing capacity of up to 12 pallets per hour
Improved working environment
  • Significantly less manual handling of heavy boxes
  • Increased safety via the robots’ LiDAR-based safety system
Flexibility and operational reliability
  • AMR robots navigate automatically and avoid obstacles
  • Easy expansion with additional robots
  • Central fleet management ensures high uptime

 

Reference

“CESTEK provided the best solution and came across as professional and thorough throughout their approach to the project. They quickly understood our challenge.”

Brian Rasmussen, COO/Deputy Managing Director, SKY-LIGHT A/S