Logistics automation to standardise food production and distribution

The Challenge

Committed to achieving the highest standards in food safety without sacrificing overall process efficiency, Tianfu Smart Kitchen was actively looking for an end-of-line logistics automation solution to standardize critical manual and semi-manual operations, among which storage, packaging, and end-of-line transfer operations. Furthermore, the system would need to work seamlessly within the central kitchen’s production line and in the staging area of semi-finished goods. 

To achieve these objectives, Tianfu Smart Kitchen identified critical operational areas for which it asked Comau to intervene: automating its production lines, palletizing, and handling processes, maximizing space and improving production efficiency.

A further challenge came from the complexity and precision required by the extensive warehousing operations, as items would need to be stored efficiently for quicker and more accurate retrieval when they were needed. This requires the use of Automated Storage and Retrieval Systems (AS/RS) equipped with the right robots and conveyors for rapid loading, unloading and transportation. For end-of-line conveying, Comau would also need to ensure that the product could be accurately sorted, packed, and distributed. This goal would require the development of efficient automated sorting and packing systems that could guarantee high precision and productivity.

The Solution

Comau cooperated with system integrator Xinglu Intelligent Packaging (Kunshan) Co., Ltd. (hereinafter referred to as “Xinglu Packaging”), a Xingpack Group company, to design and build a comprehensive robotic solution, including intelligent software and hardware, for Tianfu Smart Kitchen. The logistics automation solution, which is installed at the end of the central kitchen’s production line and in the staging area of semi-finished goods, significantly improves the operation efficiency of food packaging and end-of-line transportation. 

Because the huge production volume puts extremely high demands on accessing goods, it was imperative to automate the intelligent access solution to utilize less space while ensuring both performance and low labor intensity. To achieve this, Comau and Xinglu Packaging jointly designed an innovative, octagonal three-dimensional warehouse for the semi-finished goods staging area. In particular, the octagonal structure of the rack combined with the Comau robot maximizes the use of space in the limited storage area. As such, it is both more efficient and improves space utilization compared to the previously used circular, three-dimensional warehouse. It is also more flexible.

After analyzing and calculating the daily production volume, Comau deployed seven high-speed NJ-110-3.0 palletizing robots at the end of the production line. With a working range of up to three meters and a duty cycle of up to 2,100 times per hour, Comau’s robots easily exceed the required efficiency by Tianfu Smart Kitchen. 

As for the software, the commissioning team used Comau Palletizing Motion to plan tasks and actions for the NJ-series robots. They then continuously optimized the trajectory and orientation of the robotics program, including variable storage bin sizes, storage bin movement modes, automatic return to the nearest storage bin and other dimensions. Such optimization has added flexibility to the overall warehouse management system, allowing the robot to reach the designated storage bin faster and thus satisfy both the solution objectives and improved output capacity.