PPMA 2021 Preview: New UniPAKer actions energy & ready meal waste

By lowering compressed air consumption in the generation of vacuum by up to 45 percent, the overall carbon footprint of the system is significantly reduced. The single dual-head crate packing cell simultaneously reduces supply chain waste by minimising damage to protective ready meal films. 

Taking the lead to reduce automation carbon emissions and meet the UK’s new 2050 net zero targets, Brillopak has re-engineered the UniPAKer’s compressed air pressure system and end-effector vacuum generators. Creating sustainable value across the entire packing cycle, by adopting this ‘whole system airflow approach’ and improved control
and distribution of air, Brillopak reports a 10 percent reduction in power usage compared to previous models in the series.

Central to this upgrade, which features in all new UniPAKer systems and can be retrofitted onto existing UniPAKer cells, is the introduction of vacuum generators into the end-effector head. Rather than sitting external to the end-effector, air is drawn into the centre of the head and fed to each of the five generators, all of which are contained within a special internal casing, delivering more consistent, targeted and faster airflow. 

The small footprint
single-robot system is highly efficient at picking up and moving up to 70 chilled and ready meal products per minute. For example, two selection dips or two family-sized convenience meals. With the new dual-head, patent-pending end-effector design guaranteeing consistent lifting capacity when suctioning up and gently placing meals of various weights, sizes and packaging types into retail crates. 

“This gentle handling is especially imperative when handling thin films, pillow bags, resealable packs and newer more sustainable packaging substrates,” emphasises David Jahn, Director at Brillopak. 

Taking action against the nine million tonnes of
food wasted annually in the UK – which, alone, accounts for 25 million tonnes of carbon emissions (the equivalent of ten million cars) – the next-generation UniPAKer also helps to address one of the biggest avoidable waste hotspots in ready meal production and distribution: split top seal packaging and torn film lids.

“Spillages are one of the key causes of ready meal waste. On high-speed side or drop loading automated production lines, one broken seal on a ready meal has the potential to tip and cross-contaminate an entire tray,” notes Jahn. 

With a
ten percent smaller footprint than earlier UniPAKer generations, one cell can handle multiple product types and place them into crates in multiple patterns. 

Striking the optimum balance of fast acceleration and gentle pick and placement, the new UniPAKer is especially beneficial for crate loading perishable products which are more prone to leaks and damage, including meat, fish, ready meals and fresh produce. At PPMA 2021, Brillopak will showcase the single dual-arm delta robot picking up and placing ready meals into retail crates. Depending on applications, a single UniPAKer cell can be configured to incorporate up to three robot configurations working in unison.