Why automate depalletizing and bag opening in the food industry?

Do you manage a production line where operators handle 25 kg bags daily?
Are you facing issues related to arduousness, dust, throughput, or food safety?

In the food industry, manual bag opening remains a well-established reality in many factories. However, this repetitive step can be fully automated thanks to current robotic technologies with intelligent 3D vision.

No more risky, highly arduous tasks, cutter cuts, dosing errors, physical strain, and operator exposure to dust, sometimes CMR. Thanks to robotic depalletizing equipment with 3D vision combined with an automatic opening station, you can:

• Save time with each batch,
• Improve the hygiene of your process,
• Reduce risks for your operators (dust exposure, MSDs, etc.),
• Improve the reliability of your entire supply of raw materials and ingredients.

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Manual bag handling in production areas is time-consuming, demanding, and a source of musculoskeletal disorders (MSDs).

Operators lift 25kg bags, which, at the end of the day or week, represent several hundred tons! Robotic solutions also eliminate repetitive movements and the handling of sharp tools.
In a 3x8 shift, fatigue accumulates, the risk of accidents increases, and the quality of movements decreases considerably.

The robot with integrated vision allows:

• to identify the position of the bags on the pallet,
• to grasp each bag with a suitable gripper,
• to transport it to an automatic opening station,
• to improve consistency, hygiene, and traceability.

Manual bag openings present numerous areas of variability:

• Irregular cuts,
• Product leaks,
• Missing a bag bottom,
• Unsorted packaging mixes.

With a robot and an automatic cutting station, opening is precise, clean, and systematic, regardless of the throughput.

The process becomes:

• Traceable (number of bags, batches),
• Reliable (no omissions or duplicates),
• Hygienic (no human contact with the product).

Palamatic Process robots, such as the Sackbot® 200-M3, are equipped with 3D cameras and vision software capable of automatically detecting:

• The exact position of each bag,
• Its geometry,
• Its stability or deformation,
• The gripping technique adapted to agricultural bag formats.

The cell is therefore capable of handling mixed, incomplete, or slightly offset pallets, without manual adjustment.

Once located, the bag is gripped by a specific gripper with articulated claws for porous bags or vacuum suction cups. These tools ensure reliable gripping without creating dust. Handling is smooth, stable, and compatible with throughputs of up to 10 bags/minute.

Automation guarantees maximum hygiene and frees operators for higher value-added tasks (quality control, line management, maintenance)

1. What are the main benefits for the operator? 

Automation eliminates laborious handling, repetitive movements, carrying loads, and the use of sharp tools. The operator gains in safety and comfort, and can focus on control or quality control tasks.

2. Is robotization cost-effective for medium-volume production? 

Robotization is cost-effective for medium-volume production thanks to its modularity. Robotic cells are suitable for both high-volume and intermediate production. The time savings, error reduction, and elimination of laborious work ensure a rapid return on investment.

3. Can all types of bags be opened automatically?

Les systèmes de Palamatic Process systems are designed for a wide range of bags (kraft paper, lined, thick, small formats, etc.). The grippers and cutting stations are configurable according to the type of packaging used.

4. What types of products can these systems handle? 

All dry products packaged in bags: sugar, flour, starch, cocoa powder, vegetable proteins, additives, technical ingredients, etc. The equipment is designed to meet the strictest food hygiene standards.

5. Are the cells ATEX compatible? 

The design meets ATEX requirements. The components in contact with the products (bag dumpers, hoppers) are made of brushed or polished stainless steel, with antistatic systems and suitable filtration. The robots can be covered to ensure arm containment.

Automating depalletizing and bag opening in the food industry is much more than just a productivity boost. It's a comprehensive improvement process: better ergonomics, better hygiene, fewer errors, and greater consistency. Today, these technologies are accessible, proven, and adaptable to any size workshop. It's no longer a question of whether you should automate this step, but when.

 

👉 Need an audit or technical study? Contact the experts at Palamatic Process