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Baxter cases with unerring accuracy

A robot places and counts blisters containing IV packs into cases with an accuracy that has reduced complaints. Setup also uses case erector and sealer.

Baxter's robot picks up four blister packs at a time using a hinged gripper for placement into the cases.
Baxter's robot picks up four blister packs at a time using a hinged gripper for placement into the cases.

Baxter Healthcare’s Medication Delivery plant in Aibonito, Puerto Rico, features a case-packing operation anchored by a robot. The robot fills the cases with blister packs that it picks up using a custom, hinged gripper with vacuum cups. The cases are erected and, after filling by the robot, are sealed on the same integrated system.

The UP6 robot with XRC controller and Flexview® 1000 touchscreen panel interface is supplied by Motoman (West Carrollton, OH). The case-erecting and sealing portions comprise an Ergopack® system with automatic case erector, sealer, and controls from Combi Packaging Systems LLC (Canton, OH). The robotic packer replaces a hand-pack station in the Ergopack layout. It also includes a powered belt-type, case infeed conveyor with side-grip rails, and top and bottom case sealer.

Other components include slipsheet stand, 8’-long powered infeed conveyor, and 4’-long powered belt conveyor that spaces the product for the robot. The preassembly and integration of the equipment was done by Motoman.

Baxter engineering director Manuel Garcia reports that the main benefit of this setup is the labor savings from not having two to four operators manually forming cases and loading them with the packs.

The boxes are packed in three different configurations: 12-, 20-, and 48-count sizes. The robot cycles in about five seconds, Garcia relates. The packing time per case ranges from one or two minutes for the small sizes to three to four minutes for the 48-count size.

Although that’s hardly a blistering pace, the robot’s real value is in its accuracy. “We avoid complaints of over- and under-count cases,” says Garcia. The robot normally operates for two eight-hour shifts five days a week.

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