RP-Y Robotic Pouch Case Packing System
Statera’s robotic pouch case packers were originally designed and manufactured for a laundry product application by ZARPAC’s custom equipment design build group. The application required a single machine that offered the versatility to load pouches from 200 mL to 2 L in either vertical or horizontal orientations. The initial models went into production in 2014, and they were so successful that the customer standardized on them for stand-up pouch filling lines around the world.
Based on interest from other manufacturers, Statera is designing, building, and supporting RP-Y robotic pouch case packers for customers requiring versatile pouch case packing capabilities. They employ an innovative design that integrates a robot with a mechanical pouch collating and loading system to achieve unmatched flexibility. Servo-controlled conveyor flights automatically align, space, and group pouches into recipe-specified layer configurations and locate them in precise position for smooth picking by the robot.
When pouches require vertical in-case orientation, a collating tray system is loaded by the robot, and when the tray loading process has been completed, the collating system gently secures the pouches, rotates, and releases the pouches into each case. When pouches require horizontal in-case orientation, the collator automatically retracts, and the pouches are loaded directly into cases by the robot.
RP-Y robotic case packers are ideal for production lines that require both vertical and horizontal pouch loading capabilities as well as the ability to handle both dry and liquid products on the same machine. They are also capable of handling and loading pouches with or without fitments. They handle multiple pouch styles, including true Doy-style stand-up pouches, modified Doy-style stand-up pouches, pillow pouches, 3-sided seal pouches with or without tuck, 3- and 4-sided flat pouches, and bag-in-bag pouches.
RP-Y systems are available in single-cell or dual-cell configurations. Dual-cell models offer increased throughput and independent operation, which supports non-stop operations. Single-cell systems offer speeds up to 100 pouches per minute and dual-cell systems offer speeds up to 200 pouches per minute, depending on pouch size and case pack configurations. RP-Y pouch case packers also feature a space-efficient design in which two full sets of change parts can be stored within the frame and footprint of the machine, with no separate change part carts required.
Features & Capabilities
- Vertical and Horizontal Pouch LoadingSupports multiple case pack configurations that require loading in either orientation; reduces capital investment and increases line flexibility.
- Six-Axis RobotProvides a wide range of motion and precise adjustment capabilities to accommodate a variety of product configurations.
- Pouch Sizes from 200 mL to 2 LProvides versatility to run a wide range of pouch sizes, which helps maximize line utilization.
- Liquid and Dry Product HandlingThe system design accommodates pouches filled with either liquid or dry products.
- Accommodates Stand-Up and Horizontal Pouches, with and without FitmentsFull compatibility with true and modified Doy-style, pillow, 3-sided seal (with or without tucks), 3- and 4-sided flat, and bag-in-bag pouches provides unmatched production flexibility.
- Narrow-Edge and Wide-Edge Case Loading and FeedingSupports multiple case sizes, styles, and types.
- Toolless ChangeoversFast and simple; two to five minutes per cell depending on pouch sizes, pouch types, and case configurations.
- Vision SystemAssures pouches are in correct position to enable smooth handling and loading.
- Pouch Detect-Reject SystemsIdentifies out-of-specification pouches and automatically rejects them onto an integrated reject conveyor.
Specifications
| Speed (Single Cell) | Up to 100 pouches per minute Depending on pouch size and case pack configurations |
|---|---|
| Speed (Dual Cell) | Up to 200 pouches per minute Depending on pouch size and case pack configurations |
| Pouch Size Range | 200 mL–2 L |
| Pouch Orientation | Vertical or horizontal |
| Pouch Styles | True Doy-style and modified Doy-style stand-up pouches; pillow pouches; 3-sided seal pouches with or without tuck; 3- and 4-sided flat pouches; bag-in-bag pouches |
| Products | Dry and liquid products on the same machine; pouches with or without fitments |
| Robot | Six-axis robot |
| Configurations | Single cell or dual cell |
| Changeover | Toolless; two to five minutes per cell Depending on pouch sizes, pouch types and case configurations |
| Case Loading | Narrow edge and wide edge |
Two cells that run independently — so one stopping doesn't stop the packing
Order the RP-Y as a single cell or as a dual cell system in which each cell operates independently. Single cell systems run up to 100 pouches per minute and dual cell systems up to 200, depending on pouch size and case pack configuration — and because the cells are independent, dual cell operation supports non-stop production.
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