Company Overview

Industry

Food

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Location

Ireland

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Number of Employees

180

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Products

Palletizing Solution

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Step 1 - Box dimensions, weight and orientation

So really it's a very quick, fast, simple solution, and it's one that can be rolled out at pace across multiple lines within a factory.

Ken Maguire

Managing Director, Glenhaven

The Problem

The company faced several pressing issues:

Inconsistent Productivity: Manual palletizing led to fluctuating work pace, resulting in idle time and inefficiencies.
Labor Shortages: Difficulty in hiring and retaining workers made it challenging to sustain operations.
Rising Costs: Increasing labor expenses put pressure on margins.
Automation Hesitation: With no prior experience in robotics, they were cautious about making a large upfront investment.

Fortunately, their newly-appointed Managing Director had previously implemented Robotiq Palletizing Solutions at another company and recognized its potential for this operation.

The Solution

Robotiq’s PE20 palletizer offered the perfect fit for their needs:

Turnkey Simplicity with a single point of contact: A complete solution that eliminated the complexity of managing multiple suppliers.
Ease of Use: Intuitive software enabled quick input of box dimensions, weight, and pallet configurations, requiring minimal training.
Proven Reliability: With nearly 700 installations worldwide, Robotiq’s track record provided confidence in the solution’s performance.
Scalability & ROI: The company adopted a phased approach, automating one line first before scaling up. They will achieve a 13-month ROI, with further improvements expected as the second phase rolls out

Installation Services

Robotiq’s Installation Services applied the Lean Robotics methodology to the Glenhaven Project, as we do with all of our projects. This means starting simple and bringing added value. Once we scoped Glenhaven’s needs, discovered why they wanted to automate, and what they wished to achieve, we began to study their manual process and how to automate it.

DESIGN

The design process started with a kickoff meeting between Robotiq and Glenhaven to review the business proposal. We held weekly meetings throughout the process, keeping Glenhaven informed of every project development and addressing any questions they had. Everything was reviewed and submitted for approval before manufacturing and shipping. This process usually takes four to six weeks, depending on the complexity of the project.

INTEGRATE

Companies have the option to undergo a Factory Acceptance Testing (FAT) to minimize risk or speed up deployment. During a FAT, Robotiq tests anything that has to be done custom as well as any potential risks that we see or that the customer sees.

A typical installation is completed in just three days. One day for physical setup and assembly, a second day for operating in production, fine-tuning the program, and adjusting the palletizer for optimal performance, and a third day for training and Site Acceptance Test (SAT).

OPERATE

For Glenhaven, additional modules were added, including a custom gripper designed for various box sizes and shapes, a two-zone infeed system with gating for controlled accumulation, an interlayer feeding system, and a safeguard system with safety scanners. The solution can operate 15 boxes per minute and all 25 different SKUs produced on this line at Glenhaven.

Applications

Palletizing

By implementing Robotiq’s PE20 palletizing solution, Glenhaven optimized operations, reduced labor dependency, and set the foundation for continued growth. Their experience proves that automation doesn’t have to be overwhelming—it can be a practical, step-by-step process with significant benefits.

Discover Robotiq Palletizing Solution