Maluka speeds up food cartoning process with OMRON servo drives
RaceTrack Function Block simplifies complex motion control
To help a major food producer automate a complex cartoning process, Maluka developed a high-speed, multi-format packaging machine powered by OMRON’s Sysmac automation platform.
Key Benefits
Efficient handling of horizontal and vertical product orientations in one system
High-speed operation with up to 320 products per minute
Flexible, modular transport using OMRON’s RaceTrack Function Block
Compact design replaces two machines with one, saving space and cost
Fully integrated Sysmac automation platform with motion, logic, safety, and HMI in one environment
At-a-Glance
The process of packing products into cartons in two different ways is problematic for a single machine, which is why companies often require two. To meet this challenge at a major food producer in Poland, the Maluka team undertook the design, production and implementation of a cartoning machine for hamburger steaks, using OMRON technology.
The machine handles two product orientations, horizontally and vertically, at speeds of up to 320 units per minute, replacing the need for two separate systems. Key to the solution is OMRON’s RaceTrack Function Block, enabling precise control of the racetrack-style transport system for accurate grouping and transfer. With 1S servo drives, integrated safety, and a PackML-based HMI, the solution delivers maximum flexibility in just 3.5 m² more space than a standard setup.
The challenge: High-speed grouping with two product orientations
The basis of the solution created by Maluka is a cartoning machine, which uses a suction cup to pick up a carton from the magazine, opens it using a second suction cup and places the formed carton on a feeder. The products are inserted on this feeder, hot glue is applied and the open walls of the carton are closed and pressed.
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“This may sound simple, but there are two challenges here. The first serious task is to collect the products at a speed of 320 pieces per minute. The second, more difficult task is to group these products, once horizontally into columns, once vertically into rows.”
