Robotics are moving up the production line and bringing with them increased safety and productivity benefits. Shifts in robotics use are reported in a newly released business intelligence study from US trade association for packaging and processing technology, PMMI. "Trends in Robotics Market Assessment 2014" is an update on its 2008 survey. Robotics have surged forward since then.
"Robotics got their start in palletizing. Now they're coming up to the front of the line, for processing and depalletizing." [report author Donna Ritson, president, DDR Communications]. Advancements in robotics over the nest five years have the potential to accelerate that move.
"What we heard in our interviews mirrors much of what we've been seeing at PACK EXPO," Ritson continued. "When we studied the robotics marketplace in 2008, only 20 percent of manufacturers used robots to package their products. Today, 75 percent of end users use robotics at some point along their manufacturing lines, and the capabilities for food and pharmaceutical processing are game-changers."
What are the key trends in robotics directing their rapid assimilation into packaging lines?
1. Robots that see more clearly: vision sensors increase the precision and handling of objects - distinguishing differences in size, shape and colour.
2. Robots with greater manual dexterity - a variety of end-of-arm-tooling devices [EOATs] have made robots nimbler for product handling. Advances in EOAT design are being made to claws, grippers, pinchers, magnets, vacuum and suction devices.
3. Integrated controllers – as robot use has expanded throughout both the processing and packaging lines, robot manufacturers and integrators are finding benefits in using a PLC to control the robot directly, in place of the manufacturer's native control. Robots can perform more advanced applications by using their own 'brains', programming is easier and the robots are more intuitive.
4. Sanitation improvements will allow robots to have direct contact with food – robots are being designed robots with smoother surfaces without angles or corners where bacteria can be trapped and tighter seals that lock out contaminants for washdown. Corrosion resistant surfaces can also be washed with bacteria killing chemicals to make the surface and EOAT aseptically clean.
5. Safety and efficiency advantages - Robots can run 24/7 without a break and can lift heavy loads faster than most human workers without risk of physical injury. There are cost savings because robots can perform high speed, repetitive manual tasks that are not economically viable for higher wage, skilled workers. Advances in controller software make it possible to dictate the robot's range of motion and operating speed to allow a human worker to perform tasks alongside it without risk of being struck by the rotating arm.
6. Decreasing costs that make robotics more affordable
"Although robotics are integral to replacing manual labor and reducing operating costs, they're also creating new job opportunities. The manufacturing worker of tomorrow will need to have a higher level of technical training to design, integrate, operate and maintain robotic technologies. Expect to see growth in job functions such as integration services, mechatronics engineering, robotic training and operating, and PLC and servo programming," Ritson concluded.
To download the report (free to PMMI members; US$3,500 for nonmembers).
PMMI owns and produces PACK EXPO International 2014 in Chicago; November 2–5, and is working in partnership with the International Society for Pharmaceutical Engineering to produce the co-located Pharma EXPO. The two events will feature robotics in action and draw about 50,000 packaging and processing professionals. Find out more here.
