FOLLOWING PERSISTENT challenges with accuracy and ingredient wastage during a previously manual handling process, Cornwall-based Western Mechanical Handling UK (WMH) was tasked by its end-customer with automating the delicate transfer of decorated caterpillar cakes onto the supporting tray prior to packaging. 

Key issues with the manual process included inconsistent positioning on the tray, which could lead to quality issues, including product rejection and reduced overall throughput, as well as excessive use of chocolate ganache, contributing to unnecessary cost and ingredient wastage. 

Handling decorated cakes without damage

To balance delicate handling requirements with accurate positioning and ingredient dispensing, WMH turned to long-term automation partner Mitsubishi Electric for support with the system build. 

WMH’s unique soft gripper design, specially customised for food-grade applications, is at the centre of the new system. The gripper mimics the sensitivity of a human hand and enables the delicate handling of decorated cakes without disturbing their finish. 

The grippers are mounted on two Mitsubishi Electric RV-7FRLM-D 6-axis robots with a 7 kg payload, supported by an R86TB touchscreen robot teaching box. 

Both robots were mounted overhead to help reduce the overall footprint of the finished cell and are rated to IP65, supporting operation at the end user’s site, which mandates strict cleaning and hygiene requirements throughout its 24/7 operation. 

"With food production, there is no room for error, and any downtime or product wastage, no matter how small, can very quickly add up," explained Ian Ewing, system sales engineer at WMH. "With our customer experiencing persistent issues with their previous manual handling process, we were tasked with delivering a cell that would mimic the dexterity and delicacy of the human touch, combined with the precision expected from an industrial automation system. Having worked with Mitsubishi Electric for a number of years, we were confident the robots could deliver the positional accuracy and repeatability needed to complement the sensitive handling capabilities of our gripper head.

Speed critical to maintaining throughput

"Speed was also very much of the essence. If the conveyor stopped whilst the robots synchronised with the products, throughput would be impacted, creating a knock-on effect throughout the production process," he continued.

"As a result, we needed the robots to track the conveyor and pick cakes that were continuously moving. Given how easy the Mitsubishi Electric robots are to program, this was achieved with relative ease." 

The project’s tight operational parameters for speed, accuracy and productivity required Mitsubishi and the WMH team to work together closely to specify the robots best suited to the application, said Jewel George, robotics product manager at Mitsubishi Electric Automation Systems Division UK.

"The RV-FR series is among our most versatile, and we were able to collaborate closely with WMH to support the supply, installation and programming of the robots. With the cell now operational at the end user’s site, throughput and quality are performing well above those of the previous manual process," she concluded.  

For more information:

gb-fa.mitsubishielectric.com

Tel: +44 (0)1707 288790