Food processing and packaging facilities are moving increasingly toward robotics. Automation has revolutionized the food industry, helping manufacturers reduce human error, meet consumer demand, and overcome hurdles like labor shortages.
From task-oriented robots to advanced machine learning and innovative vision systems, automated packing constantly evolves to become even more efficient and cost-effective. Explore the latest trends in robotic packing for the food industry.
Advanced Robotics in Primary Food Packaging
Robotic packing technologies, specifically newer delta robots, are transforming food packaging. These robot models are perfectly suited for primary food packaging and labeling tasks that require flexibility and precision. Furthermore, the parts that touch food items are easily cleanable and made from food-safe materials.
Fast and accurate, advanced delta robots can pick, package, and place products much more quickly than older robot models, enabling faster processing. Thanks to features like interchangeable grippers and lifting by suction, these robots are versatile enough to handle even delicate products like eggs, pastries, and air-filled snack packets without damaging them.
Food manufacturers can boost efficiency and save a bundle in labor costs by delegating low-level, repetitive processes to robots. Meanwhile, food industry workers can focus on more meaningful tasks that need a human touch.
Integration of Artificial Intelligence and Machine Learning
The food industry now extensively uses AI to streamline processes and reduce waste. AI systems can instantly crunch data to make robotic packaging even more efficient. For instance, AI can analyze product characteristics like size and shape to suggest the best packaging method. AI can also supervise packaging to ensure high-quality, uniform packing.
This system relies on reinforcement learning (RL), a type of machine learning that provides feedback to promote goals like efficient or careful packing. RL can “teach” robots to save space while packing or adapt their movements when handling vegetables or other food products with irregular shapes.
How does this work in real life? The beverage giant Coca-Cola uses AI technology for barcode scanning. When the AI system recognizes a damaged or misaligned barcode, it adjusts the packaging process automatically, reducing the need for manual intervention and improving efficiency.
Collaborative Robots (Cobots) in Packaging Lines
Collaborative robots, a.k.a. cobots, work in food packaging alongside human staff. They typically handle physically rigorous or repetitive tasks, while employees focus on more complex processes. Food production facilities use cobots to transfer items from conveyor belts to packaging trays, label food containers, or sort food items by shape and size.
Cobots are adaptable and easily programmable to handle various packaging tasks. Operators can reassign them to different processes as needed. Cobots can also adjust grip positioning and strength while handling different products, such as hard or soft fruit.
Thanks to advanced safety features, collaborative robots can work alongside human laborers in a safe, low-risk environment. Adjustments like resistance sensors, anti-collision systems, and safe designs with rounded edges protect workers who share their space with cobots.
Adoption of Vision Systems for Quality Control
Advanced vision systems are among the most powerful trends in robotic packaging for the food industry. These cutting-edge systems use sensors, cameras, and AI algorithms to find packaging defects. Food companies rely on these tools to control product quality and resolve issues before food products proceed to distribution.
Vision systems can flag damaged seals, misaligned labels, dents, wrong colors, and other packaging defects. They integrate seamlessly with production lines, capturing and analyzing images in real-time. The appropriate rejection mechanisms can then remove defective items without stopping production. The entire process is much faster, cheaper, and more efficient than manual checks.
Advanced vision systems can also monitor fill levels, preventing over- and underfilling. This can dramatically reduce product waste, customer complaints, and costly recalls. Moreover, catching a defect early in the production line can prevent scrapping a whole batch.
As a real-life example, Nestlé applies vision systems to confirm the presence of plastic scoops in supplemental nutrition containers. When Nestlé decided to switch from colored scoops to transparent ones, which are easier to recycle, their automated inspection systems could no longer detect the scoops. The company resolved this challenge by upgrading to a new system based on deep learning.
Sustainability and Energy Efficiency
Robotic packing and AI automation help promote the overall goals of sustainability and energy efficiency in the food industry. Current robot models feature energy-efficient motors geared for consuming minimum power. They also use AI algorithms to devise efficient motions and may enter a low-power mode when not in use.
Compact, agile packing robots can work in small spaces. They need less lighting and climate control than human laborers. They are also highly precise when using packaging materials, which reduces waste.
Moreover, robotic construction often utilizes sustainable materials like lightweight alloys that save energy during operation. Robotic arms, frames, and other elements tend to incorporate recycled components. Robot design typically makes it easier to replace parts rather than a whole unit, aiming for sustainability and longevity.
Robotics in the Future
These are exciting times for the food industry. Leading manufacturers are tapping into robotics, automation, and AI to improve workflows and deliver higher-quality products.
Robotics and automation can help manufacturers overcome challenges related to food packaging, such as worker shortages, the need for increased production, and human error. Automated processes also play a huge part in quality control. They minimize the number of defective products reaching the market and reduce liability risks.
Robotics and AI technology are still in their early stages, so future systems will likely offer even more advanced features and smarter algorithms. As we observe the massive shift toward automation, it’s probably safe to say that the role of robotics in food processing will continue to evolve, making the food industry safer, more efficient, and more sustainable.
As a food manufacturer or distributor, you need a trusted robotic packaging system. At TDI Packsys, we stay on top of trends in robotic packing for the food industry. We offer a selection of robotic packing solutions for a wide range of applications. Contact us to learn more about our advanced packaging automation systems.