When a leading caulk manufacturer decided to tackle labor shortages and inefficiencies at the end of their production line, they found the perfect fit in Robotiq's Palletizing Solution. Here’s how they transformed their operations and set the stage for scalable success.

Customer Profile

This customer operates in the construction material industry, specializing in caulk production. Their products, essential for construction and home improvement projects, are shipped in boxes requiring careful handling and palletizing.

Photo Credit:  Vecteezy

Business Challenges 

To capitalize on their expertise in caulk production, the company needed to solve several challenges that hindered their growth and efficiency:

1. Labor Shortages: Staffing their end-of-line palletizing operations required dedicated workers for each line, creating a significant burden, especially across two shifts.
2. Space Constraints: Their initial consideration of centralized palletizing systems revealed that these solutions consumed too much space and required extensive conveyor rerouting.
3. Cost & Risk: Centralized systems require an important rearrangement of the production flow and the addition of costly conveyor systems. It introduces a single point of failure in your production flow. Centralized cells require industrial robots with a log reach and safety fences, consuming a lot of precious floor space. If the centralized palletizer goes down, all the lines leading to it stop. The high cadence and payload of the system make it very difficult to replace with humans temporarily in the case of an issue
4. Flexibility Needs: The company needed a solution capable of handling multiple case sizes and orientations, ensuring adaptability across different product lines.

Why Was Robotiq’s Palletizing Solution a Good Fit?

After exploring their options, the manufacturer chose our palletizing solution for its unique advantages:

• Compact Footprint: Unlike bulky centralized systems, our solution offered a small footprint that fit seamlessly into their existing setup.
• Ease of Use: Intuitive software features, such as advanced trajectory planning and simulation tools, enabled quick deployment and minimal operator training.
• Cost-Effectiveness: With a projected ROI of under two years, the solution aligned perfectly with their financial goals.
• Scalability: The ability to implement the solution line by line provided a manageable pathway to full automation without overwhelming their resources.
• Resilience: Even if one line goes down, the rest of the factory still produces. Plus, the lower cadence makes it possible to temporarily assign palletizing labor while the system is put back in production.
• Local Support: Collaboration with a local partner ensured smooth integration, including custom conveyor designs and gripper configurations for optimal performance.

Tips if You're Considering Automation

For businesses exploring automation, here are key takeaways from this success story:

1. Start Small: Deploy automation one line at a time to minimize risks and achieve early wins. Scaling becomes easier once the first system proves its value. This is one of the principles of our Lean Robotics methodology.
2. Focus on ROI: Prioritize solutions that deliver quick and measurable returns, like Robotiq’s Palletizing System.
3. Choose Flexibility: Opt for adaptable systems capable of handling diverse product requirements without major reconfigurations.
4. Partner with Experts: Work with reliable suppliers and local partners to ensure seamless implementation and ongoing support.
5. Think “Outside of the Box”: Don’t overlook end-of-line processes like palletizing when seeking automation opportunities. These tasks often yield significant ergonomic and efficiency benefits.

Conclusion

This caulk manufacturer’s journey highlights the transformative power of automation. By choosing Robotiq’s Palletizing Solution, they overcame labor challenges, optimized efficiency, and unlocked scalable growth opportunities. 

Want to learn more about the difference between Centralized Palletizing and Lean Robotics? Download the Automated Palletizing Buyer Guide.

Ready to take the first step toward automation? Consider starting with the end of your production line—it might just seal the deal for your success. Talk with one of our experts.