A new robotic corrugated box palletizing system for FFG lines was installed and launched in the production and warehouse complex GT conveyors (GK GT Group), in the demonstration workshop.

The GT conveyors complex is 20,000 sq.m. an area adapted for heavy equipment and including 4 buildings: an equipment modernization workshop, a metalworking workshop, an equipment storage warehouse and a spare parts warehouse.

This robotic system is used in factories producing and processing corrugated cardboard. The equipment is designed for palletizing corrugated packaging: boxes and trays made of corrugated cardboard folded into bundles.

Corrugated packaging is produced on folder-gluing lines (FFG). Corrugated boxes are stacked in packs of 10-30 pieces. and tied with a strap. Further along the conveyors they go to the palletizing system for further stacking in bales. Formed transport packages in the form of bales on pallets are delivered to the warehouse and shipped to customers.


Unique S-Robot

The main element of robotic palletizing systems is the industrial robot ABB IRB 660 or Kawasaki CP180L, with a payload of up to 180 kg. The robot stacks products in bales using a specialized gripper designed to suit the characteristics of corrugated products.

The system works with packs produced on FFG lines, Mini and Middle formats: from 290x330x60 mm to 1050x1250x480 mm, and forms bales up to L1600xW1600xH2100 mm when working with pallets and D1800xW1800xH2200 when working without pallets.

S-Robot is the first robot in Russia that operates at a speed of up to 36 packs per minute, which meets the requirements of the most modern high-speed lines in the corrugated industry.

By itself, it is very compact and versatile. Its main difference is the absence of speed loss on complex types of laying, such as: a well, 2 + 1, etc., where each pack is rotated at its own angle; here, unlike similar systems, special additional equipment is not required to turn the pack , since the robot rotates the bundles in the air while moving the bundle towards the bale.

The S-Robot is capable of placing bottom and middle sheets on pallets, which is comparable to the larger classic palletizing robots.

The robot is completed with a bale leveling device after stacking.

The robot grip has an increased height of up to 680 mm – this allows you to take two packs up to 340 mm high at once. In single pack mode, the grabber can handle packs up to 480mm high.

Patented robot grip

S-Robot has special clothespins on the grips – a special movable device for fixing the sheet. With their help, the equipment quickly and safely grabs the intermediate sheets and places them on the bale, which optimizes the work of peripheral systems in the formation zone. The robot uses a patented gripping system in its work – movable “claws” are located on its tips for even more reliable fixation of products, which avoids damage to products and prevents them from falling out of the grip.


Continuous work

In palletizing systems, peripheral equipment plays a very important role – for feeding bundles, sheets, pallets. Each node is optimized to minimize the time required for these additional operations so that the robot arm is not distracted and waiting for one of these nodes.

The pallet dispenser can be configured to work with 12 pallet formats of various sizes. Pallets are issued in advance on the conveyor and await their turn.

For lining the bottom sheets there is a separate device that lays one or two bottom sheets in advance on a pallet or directly onto the conveyor using vacuum suction cups. Sheets can be replenished directly during the automatic operation of the palletizer.

In this way, once a bale is placed, the robot can immediately move on to the next bale, since the pallet and bottom sheet are already prepared, and the transition from one pallet to another takes a minimum amount of time.


Dual Pack Feed System for Robot – Doubler or Dabbler

The doubling device (doubling bag feeding system for the robot) is equipped with electric cylinders, a set of drives consisting of a servo motor, a ball screw (ball screw) and linear bearings. The stacking cycle is exceptional – just 2 seconds per cycle. Also, the device has a leveling pad, which is able to compensate for pack displacement up to 140 mm. left and right.


No delay

Communication between the robot and the PLC control panel is based on fiber optics, thanks to which communication between systems occurs at the highest speed, which minimizes any signal delays.

The trajectory of the stacking robot is programmed using an industrial PC. Previously, robot manufacturers used conventional PLCs, which have limitations on the amount of information processed.


Simple but ingenious solution

The system has one special unit – a mobile infeed driven roller conveyor. It is installed after the counter-ejector and bundle wrapper. In this way, we can center the workpiece so that the Dabbler doubling unit works with less loads.

On one side the conveyor is fixed, and on the other side it remains movable. To facilitate the maintenance of the strapping machine and free access to the elements of the palletizer, the roller conveyor has a lifting section.

The structure, on the one hand, will rise up – this helps to maintain the strapping equipment, for example, to change PET tapes. It also allows operators to pass, which helps to avoid safety violations.

The conveyor consists of motorized rollers, that is, each roller has its own motor.

This robotic palletizing system is fully translated into Russian and complies with all Russian standards and technical safety.

A set of palletizing equipment was specially brought to improve the skills of our own staff and those of the Customer.


The production and warehouse complex GT conveyors (GK GT Group) is located 10 minutes from the Ring Road of St. Petersburg, in the Leningrad region. The company regularly organizes viewings of this system for its customers. For visiting the production and warehouse complex and consulting, please contact the GT conveyors office at +7 812 777 15 15.