Syrup production line robotization in Phytopharm Klęka S.A. (Europlant Group)

The implementation at the Phytopharm Klęka S.A. (Europlant Group) plant is an example of effective robotization of end-of-line processes in the pharmaceutical industry. We focused on the beginning and end of the production line, where the deployment of depalletizer and palletizer stations significantly improved ergonomics and ensured process stability. For this purpose, we used FANUC PalletTool, which we implemented as one of the first companies in Poland.

End-of-line process automation: Depalletization and palletization with a FANUC cobot

Before the implementation of collaborative robots, the initial and final stations on the syrup production line required manual handling, which was time-consuming and generated a relatively heavy physical load for operators – especially when loading and unloading heavy goods. This posed a challenge to work ergonomics and flexibility of the packaging line crew.

We designed a solution based on FANUC technology, which took over these most arduous tasks while maintaining safe contact with humans, thanks to certified safety systems. Both the depalletizer and palletizer are cobots equipped with advanced vision safety systems that allow constant monitoring of the surroundings and dynamic adjustment of their operation. An immediate response to contact with an obstacle or human presence – in the form of halting or reversing movement – eliminates the need for fixed safety fencing. This opens up the production space and allows for the optimal utilization of every square meter of the hall.

Depalletizer ZWA-i20-DP01: Optimization at the beginning of the line

First, we integrated a robotic arm that handled depalletization. The cobot’s tasks included picking packs of empty glass bottles sealed in shrink wrap from pallets (small and light safepaks as well as tall and heavy ones, weighing up to 15 kg) and placing them onto the conveyor belt/production line conveyor, as well as removing interlayer sheets.

The challenge lay in the variable product weight, bottle stack height, and non-uniform surface. The robot must precisely pick packs of various dimensions and delicate surfaces, which is why we developed a dedicated gripper with soft suction cups for film and an integrated vacuum control system. As a result, the system operates stably with a precision and smoothness exceeding the initial assumptions, while ensuring full operator safety.

This implementation not only relieved workers but also ensured high efficiency, handling loads with a stack height up to 1250 mm. The throughput was confirmed at 3.4 packs/min (achieving the target of 3/min), which guarantees a smooth flow of material to the line.

Palletizer ZWA-i25-PP01: Precise palletizing of finished cartons

In parallel, at the end of the line, we designed and customized a cobot that took over the palletization of the finished product. It was tasked with turning secondary packaging cartons, scanning their labels, and palletizing them according to a selected pattern in various configuration layouts, handling packages of varying weights – up to 20 kg – and a stack height up to 1650 mm. And this goal was achieved. The project also included the possibility of using interlayer sheets. Thus, we fully automated the packaging process of finished goods.

Thanks to the use of universal silicone grippers and the innovative FANUC PalletTool module – which we implemented as one of the first companies in Poland – the system achieved a stable and required throughput of 8.05 cartons/min (achieving the target of 8/min).

FANUC PalletTool allows creating carton and interlayer stacking patterns without modifying the main program. As a result, Phytopharm Klęka employees can independently add new carton palletizing references while maintaining the assumed throughput and process repeatability.

During the implementation of the palletizing system project, beyond the layer-forming process itself, we focused on precisely tailoring the line to the customer’s specific quality and logistics requirements. The system was enhanced with a number of functionalities that increase the standard of control and operational flexibility:

Advanced quality control: Thanks to the integration of an additional vision camera, the system continuously checks for the presence of the logistics label on secondary cartons. Furthermore, the operator can force a random carton to be placed on a dedicated inspection area, allowing content verification without stopping the line.
Gentle product handling: We utilized a dedicated conveyor equipped with an innovative turning device. This solution allows for smooth and safe positioning of cartons of any size, guaranteeing their intact condition.
Smart packaging: The cobot performs the interlayer sheet placement process adaptively – the algorithm automatically adjusts their presence and arrangement depending on the selected product reference.

Comprehensive robotization deployment: From 3D model to SAT tests

The entire project was carried out in accordance with the highest industrial automation standards.

Concept and engineering: Based on a thorough space analysis, we created realistic 3D models in Solid Edge. This allowed for the precise selection of robot arms, control systems (Siemens TIA Portal), and dedicated gripper systems.
Execution and Programming: The prefabrication of control cabinets ran in parallel with the mechanical assembly. Communication between the FANUC cobots and PLC controllers was implemented via the Profinet network, ensuring easy operation from operator panels on tablets.
Testing and handover: After internal commissioning, we conducted official FAT (Factory Acceptance Tests) with the customer, followed by final SAT (Site Acceptance Tests) at the customer’s plant. The entire project, from the first meeting to the final acceptance protocol, was completed within the scheduled timeline (March 2024 – December 2024).

As a result, Phytopharm Klęka gained a system ready for continuous 3-shift operation, which allowed for the optimization of line staffing while ensuring process stability. At the same time, working comfort was significantly improved – the monotony of repetitive tasks and the risk of accidental injuries were reduced.

“The cooperation was very smooth, and the entire team worked hard to deliver a product on time that met our expectations. We are particularly pleased with the reliability of the new process. We now have a significantly better work culture at the beginning and end of the packaging line.” – Bartek Kwiatkowski, Project Manager, Phytopharm Klęka S.A. (Europlant Group)

Time to accelerate. Power up your production!

Phytopharm Klęka S.A., known for producing high-quality OTC medicines based on natural ingredients, including from their own unique arborescent aloe plantation, decided to leverage the expertise of both their own specialists and us as integrators, seeking solutions to support employees in simple production tasks. The company combines the power of natural healthcare products with the potential of science and modern technology – calling this combination phytotechnology. Thanks to FANUC cobots, the company has gained a reliable partner for continuous operation and paved the way for utilizing them in other processes at Phytopharm Klęka. Is your company ready to elevate the ergonomics and efficiency of its production line to a similarly high level?

Don’t wait for labor costs and physical strain to slow down your business. Call or write to us to schedule a free site visit and receive an initial, individualized concept for end-of-line automation.

Watch the video on how automation of bottle depalletization and carton palletizing at Phytopharm Klęka – supported by FANUC palletizing software – exceeds initial cobot throughput estimates, improving safety and reducing work monotony.