The system was based around a series of conveyors that transferred the boxes from the existing carton erecting machine to a position where they were inspected for gross damage and printed with appropriate information.
An ABB IRB660 4-axis robot then collected the box from the end of the conveyor and built them into pre-programmed stack formations on one of two Pallets. Once the first Pallet was filled, the robot automatically moved to fill the second Pallet allowing the operator to manually remove the filled Pallet for shipping and replace the location with an empty Pallet.
Each Pallet location was protected within a fixed guard structure with access provided via a pair of independently interlocked guard doors. Each guard door was fitted with a Castell type interlocks and light curtains to ensure the safety of the operator whilst changing pallets.