Customer case study · Food packaging automation

Complete Mpac robotic picking line
Robot picking seasoning sachets
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How do you pack 24 SKUs on one automated line?

That was the challenge a food producer brought to Mpac Langen. Seasoning sachets of different sizes, multipack combinations and stack formations all needed to be managed within one flexible system, ultimately feeding two cartoners, a case packer and a bulk station.

The answer: an integrated robotic picking solution engineered around the customer’s complete product flow.

The project demonstrates how close collaboration with technology partner Lenze, can accelerate the delivery of complex automation solutions.

The product & solution

More than different flavours

Explore the product variation
Small lightweight seasoning sachets
01

Small and lightweight

Controlled picking for lighter sachet formats.

Larger and heavier seasoning sachets
02

Larger and heavier

The same architecture accommodates larger pack formats.

Single-flavour seasoning sachet multipack
03

Single-flavour multipacks

Accurate grouping of identical product variants.

Mixed-flavour seasoning sachet multipack
04

Mixed-flavour multipacks

Different flavours combined in the required sequence.

05

From one to eight high

Collation patterns range from individual sachets to stacks of eight.

Eight robots. Four packaging routes.

 

Four independently controlled robot cells place each sachet into the bucket conveyor system.  From there, every SKU is directed to one of two cartoners, the case packer or the bulk station.

Integrated system overview
Cell 01 R1 + R2
Cell 02 R3 + R4
Cell 03 R5 + R6
Cell 04 R7 + R8
Product transport Bucket conveyor system
Seasoning sachets directed towards the first cartoning route
Route 01 VENTO cartoner 1
Seasoning sachets directed towards the second cartoning route
Route 02 VENTO cartoner 2
Products directed towards downstream case packing
Route 03 To case packing
Products directed towards the bulk handling station
Route 04 Or bulk loading

Flexibility starts before the pick 

A vision system detects the position and orientation of each sachet.
The robots then adapt every pick to create the correct collation—even when
products arrive unaligned.

Vision system detecting the position and orientation of seasoning sachets 01
Detect

Vision identifies each sachet

Product position and orientation are detected before the picking movement begins.

Robot picking seasoning sachets using vision position data 02
Adapt

The robot adjusts the pick

The sachet is picked from its detected position and placed into the required collation pattern.

01 Detect Position and orientation
02 Calculate Required picking movement
03 Pick Controlled robotic handling
04 Collate Correct product formation
Mpac engineering principle

Design the packaging solution around the customer’s product flow, rather than forcing the products into a predefined machine configuration.


Technology partnership

Developing the architecture together

Mpac Langen and Lenze worked together from the earliest engineering phase,
combining Mpac’s packaging and robotic application expertise with Lenze’s
motion-control and digital-twin technology.

By simulating and validating the concept before physical implementation,
the teams could optimise performance earlier and reduce risk during
commissioning. Mpac then developed and integrated its own reusable robotic
software layer, retaining the knowledge and flexibility to adapt future
applications.

Packaging and robotic engineering Mpac Langen
×
Motion control and digital twin Lenze
Mpac Langen and Lenze engineers working together
Joint engineering
Digital twin of the robotic picking system
Virtual validation
Engineers reviewing the robotic control software
Software development
Shared architecture Over 25 years of partnership.

Faster commissioning through virtual validation

Digital-twin validation and reusable robotic software increased commissioning
productivity from approximately one robot per week to three or four.
The complete system progressed from initial enquiry to delivery in approximately
18 months.

Commissioning productivity
Previous approach ≈1 robot per week
New architecture 3–4 robots per week
Approximately 18

months

From initial enquiry to delivery

01 Faster commissioning

More validation completed before physical start-up.

02 Reusable software

A proven foundation for future robotic applications.

03 Knowledge retained

Mpac can adapt and develop the software in-house.

24 SKUs. Four routes. One integrated solution.

Your product. Your process.

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