Case story

Advanced palletising system in state of the art premises

CSi achieved a stunning success

by designing, delivering and
installing a high-quality
palletising system at the
innovatively designed
premises of one of Hollands
largest co-packing companies situated in
Etten-Leur.
This customer manufactures and co-packs a
range of cleaning materials including detergents,
bleaches, shampoos etc. in both liquid and

powder form and also has

the facilities to produce
special one-off
promotional ranges.
This diverse product range
requires a highly
flexible production
process, with the ability to handle a wide range
of packaging formats and sizes. The original
manufacturing site had many production lines,
but all products were hand-palletised and the
design of the original building made it difficult to
automate the end-of-line processes.

Benefits:
Fully automated palletising equipment
Savings in staff costs
High degree of reliability
Sizeable capacity
Suitable for a very wide range of
packaging types
Energy-efficient design

Key data:
Sector: co-packer household detergents
and cleaning industry
Country: The Netherlands
5 end-of-line palletising lines
Capacity: 4,220 products per hour
Capacity: 40 pallets per hour

The new cutting-edge designed building

incorporates 23 production cells positioned
around a central storage area, where products
for each production cell are stored close to their
point of use. Each production cell has an out-feed
conveyor which transports finished products
towards a centralised palletising system. The
palletising system consists of 5 robot palletisers

with each robot having 3 pick positions. This

provides for the palletisation of 15 different
products at any one time. A sixth robot is used as
a means of de-stacking a wide variety of pallets
which are then fed to the appropriate robot cell

Technical highlights:
Spiral conveyor for vertical transport
6 spherical robots for maximum
flexibility
15 products palletised simultaneously
Automatic pallet transport and film
wrapping
Automatic pallet labelling

meet the highest levels of energy efficiency and

overall sustainability. Features like LED lighting
throughout the entire building, intelligent lighting
controls which only switch on when needed,
together with CSis own sophisticated controls
which ensure conveyors only run when needed all
go towards making this production unit one of the
most efficient in Europe.
From its sleek exterior to its groundbreaking

using a transfer car. This is an extremely advanced

robot palletising system, being fully automated
with very high capacities and the highest levels of
reliability guaranteed. The control system has the
ability to guide the transfer car towards the correct
pallet pick up positions for the removal of full
pallets and to replenish the empty pallet and layer
sheet storage magazines.
The main challenge for CSi was the ever-changing
range of products and the high degree of flexibility
required across the entire system. With very short
production runs and an ever-changing package
format it was essential to design a robot gripper
tool to suit both large and small packages, with
the associated controls to ensure the careful and
precise palletising of all the products.

Innovation:
Extremely flexible robot equipment for
various packaging types
Separate robot for unstacking
empty pallets
Energy-efficient design

CSi was chosen for this project due to its proven

track-record in providing innovative and highly
reliable materials handling solutions, and its ability
to work in close cooperation with its customers to
achieve all the goals set on any given project.
All aspects of the design of the new building
and the equipment operating within it had to

internal design this

project demonstrates what can be
achieved when suppliers and customers work
together as one.
Production started after a successful installation
and commissioning period in January 2010.

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