Case Studies and Complete Production Line Implementations

1. Case Study — Installation of an Industrial Robot for Palletizing 30 kg Bran Bags

Summary
Objective: To produce stable pallets — both wrapped and unwrapped — while maintaining a continuous bag‑filling and palletizing process
Challenge: A product with highly variable bulk density and an extremely limited installation space.

Challenge Details
Palletizing bran presents a unique difficulty: the weight and density of the bags vary from cycle to cycle, which means the shape and stability of each filled bag are inconsistent. This makes precise stacking significantly more complex.
In addition, the available floor space at the facility was extremely restricted, making it impossible to install a conventional pallet dispenser or a large palletizing cell. Despite these constraints, the customer required pallets that would remain stable and safe to handle even without stretch‑wrapping.

Solution Overview
Key Components of Our System Design:

Industrial robot for precise handling and palletizing of 30 kg bags
Dual‑belt bag shaping unit, ensuring each bag is formed into a consistent, palletizable shape despite variations in bulk density.
Two parallel roller conveyors: one equipped with an automatic stretch‑wrapper, another one dedicated to continuous palletizing without wrapping
Robot‑based empty pallet handling, replacing a conventional pallet dispenser due to the extremely limited installation space

Implementation and Technical Considerations

Bag Shaping: The dual‑belt shaping system supports and forms each bag from both the top and bottom. This significantly reduces instability caused by variations in bag density, weight and geometry.
The robot’s motion paths were engineered to: pick and position empty pallets; manage pallet placement dynamically; alternate between the two roller conveyors depending on system status; maintain continuous operation even when the stretch‑wrapper is running its cycle.
Space‑Efficient Layout: all equipment — including the robot cell, conveyors and shaping unit — was arranged in a compact footprint, enabling full integration within the customer’s extremely restricted floor space.
Process Logic: when the automatic stretch‑wrapper is in operation, the system automatically redirects palletizing to the non‑wrapping conveyor. This ensures uninterrupted bag filling and palletizing, eliminating downtime and maximizing throughput.

Results and Benefits

Stable Pallets Without Wrapping: The combination of precise robotic palletizing and the dual‑belt bag shaping unit ensures that pallets remain stable and safe to handle even without stretch‑film.
Continuous Production: Thanks to the dual‑conveyor layout and robot‑based pallet handling, the entire filling and palletizing process operates without interruption, significantly increasing productivity.
Space‑Saving Solution: The complete system was successfully installed within the customer’s limited available space, meeting all operational requirements without compromise.
High Flexibility: The system reliably handles variations in product bulk density, maintaining consistent pallet quality across different filling conditions

Conclusion
This project demonstrates how industrial robotics and targeted mechanical solutions can be combined to stabilize the palletizing of a challenging product — in this case, bran — while fully accommodating strict spatial constraints. The result is a robust, efficient and flexible palletizing system tailored to the customer’s unique production environment

2. Case Study — Installation of a Complete Seed Packaging Line

Summary
Objective: To install a high‑performance seed packaging line within a very limited floor space, while addressing complex material‑handling challenges.

Client Profile: Our partner is a leading seed manufacturer seeking a modern, reliable and flexible solution for the high‑volume, precise and fully traceable packaging of treated seeds. The goal was to design a packaging line capable of delivering high hourly throughput in a compact footprint, while meeting strict quality‑assurance and traceability requirements

Project Objectives

Installation of a 650 bags/hour packaging line in a highly restricted area
Gentle and safe transport of treated seeds to two separate filling points
Integration of big‑bag filling and paper bag filling within the same system
Incorporation of an 800 bags/hour palletizer in a confined space
Automatic application of two labels, including one with strict serial numbering
Development of a fully automated, auditable and ergonomic material‑handling process

Challenges and Solutions
1. Designing a Material‑Handling System for Two Separate Destinations
Treated seeds are transported from the coating unit to two different filling points using bucket elevators:

Elevator 1: Big‑bag filling station
Elevator 2: Bag filling and weighing system

One of the elevators required a 20‑meter conveying distance, demanding exceptional structural stability, vibration control and gentle product handling to prevent seed damage.

2. Installing a 650 Bags/Hour Packaging Line in Extremely Limited Space
The available floor area was significantly restricted. To overcome this:

Multiple machine units were integrated using custom support structures
Operator pathways were optimized for safe and efficient movement
Maintenance access points were minimized without compromising serviceability
Numerous design compromises and fine‑tuning steps were jointly developed with the customer

The result is a compact yet high‑capacity system capable of meeting peak‑season production demands.

3. Integrating an 800 Bags/Hour Palletizer in Minimal Space
The palletizer posed additional challenges:

High‑speed operation required strict safety and stability measures
Spatial constraints demanded customized adjustments and a modified material‑flow layout
Ultimately, the system delivers fully automated palletizing, stretch‑wrapping and top‑sheet application, all within the limited available space

4. Automatic Sewing of Two Labels, Including a Serialized One
Traceability is critical in the seed industry. The project required:

Automatic application of two separate labels on every bag
One of the labels containing strict serial numbering
High‑speed, error‑free operation despite the complexity

Our solution ensures a stable, auditable and long‑term reliable labeling process.

Results and Benefits

Performance: 650 bags/hour packaging capacity and 800 bags/hour palletizing capacity
Space Optimization: The entire system operates within an extremely limited footprint
Flexibility: Big‑bag and paper‑bag filling integrated into a single system
Traceability: Automatic application of serialized labels
Reliability: A stable, continuous‑operation material‑handling system designed for long‑term performance

Conclusion
This project demonstrated that with precise engineering, close collaboration with the customer and a deep understanding of the process requirements, it is possible to implement a high‑performance, modern and audit‑ready seed packaging line even in the tightest available space. The system now operates reliably and significantly enhances our partner’s productivity and quality‑assurance capabilities.

3. Case Study — Installation of Vertical Packaging Machines and Integration of a Post‑Packaging Palletizer

Summary
Client profile: A dry pet food manufacturer.
Objective: To improve the visual appearance of filled bags, ensure stable pallet loads and increase product shelf life.

Challenge Overview
During the filling process, the dry pet food bags trapped a significant amount of air, making stable palletizing difficult. Initially, the bags were perforated to release the air, but this negatively affected the appearance of the packaging and was not acceptable to the customer. At the same time, extending product shelf life was essential to maintain quality during storage and transport.

Our Solution

Key Components:

Installation of vertical packaging machines at the beginning of the production line
Integration of a palletizer directly after the packaging machine to automate pallet formation
Incorporation of a vacuum system into the packaging machine to remove excess air from the bags
Integration of a MAP (Modified Atmosphere Packaging) system to extend shelf life
A combined process: vacuum + MAP, followed by sealing, ensuring that the residual air inside the bag remains at 1% or below

Implementation and Technical Considerations

Integration into the Packaging Machine: The vacuum unit was designed and integrated in a way that minimally affected the cycle time of the vertical packaging machine while maintaining consistent sealing quality.
MAP Configuration: Gas mixture and dosing parameters were optimized according to the sensitivity of the product to preserve freshness and flavor
Sealing Process: Immediate sealing after vacuuming ensured an airtight closure, preventing re‑entry of air.
Palletizing: With air removed, the tight, compact bags allowed the palletizer to form precise, visually appealing and stable pallet loads that remain secure even without stretch‑wrapping.

Results and Benefits

Improved Packaging Appearance: eliminating perforation significantly enhanced the visual quality of the bags, strengthening brand presentation and shelf appeal.
Stable Pallets: vacuum‑tightened bags enabled uniform and stable pallet loads, reducing handling and transport risks.
Extended Shelf Life: MAP technology increased product freshness and durability, reducing waste and improving logistical flexibility
Process Optimization: The integrated solution minimized manual intervention and maintained production speed.
Customer Satisfaction: The combined vacuum + MAP system met the client’s aesthetic and quality expectations while improving the product’s market position.

Conclusion
Integrating vacuum and MAP technology into the vertical packaging machine simultaneously solved the challenges of pallet stability and packaging aesthetics, while significantly enhancing product shelf life. This project by Urbanpack Design Kft. demonstrates how an integrated, automated solution can improve packaging appearance, logistical stability and product quality all at once.

If You Are Considering a Complete Production Line…