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Robotic Case Packers Improve Output by 20%

German food producer Kühne realizes increased OEE for eight glass packaging formats through new case packers’ faster machine changeover and digital data gathering and networking capabilities.

Two finished jar formations are gripped by an F2 robot and placed into cases.
Two finished jar formations are gripped by an F2 robot and placed into cases.

According to Hamburg, Germany-based Kühne, its delicatessen food products are “Made with Love.” They are also made with a laser focus on high efficiency, in both product and packaging processes. Since 1722, the family-owned business has been developing innovations in food that reflect the nutritional and cooking habits of their time. Among Kühne’s current offerings—many of which are category leaders—are vinegar and dressings, gherkins, sauces and mustard, cabbage and sauerkraut, vegetables and antipasti, and “better-for-you” baked vegetable snacks sold through retail and foodservice.


Watch video   Watch a video of the two Schubert machines in operation at Kuhne.

In July 2020, the company installed two new robotic case-packing lines from Gerhard Schubert GmbH for its remoulades, barbecue sauces, and salad dressings to achieve the speed and flexibility needed for its different package formats. The new machines feature Schubert’s digital customer platform and industrial gateway, which provide analysis of key production figures that can improve OEE (Overall Equipment Efficiency) and allow Schubert to monitor the machines to improve efficiency as well as recommend preventative maintenance measures.

Robots provide gentle, efficient handling

With the installation of the two new lines, Kühne switched from case packing via a traditional grouping chain to robotics. Explains Andreas Keller, Sales Account Manager at Schubert, “Due to the high noise level and risk of breakage, the production managers at Kühne wanted an alternative to the grouping chain.” 

One of the two robotic case packing systems from Schubert handles six formats of Made for Meat barbecue sauce (shown) and salad dressings in glass bottles.One of the two robotic case packing systems from Schubert handles six formats of Made for Meat barbecue sauce (shown) and salad dressings in glass bottles.Schubert’s TLM packaging machines comprise modules that each handle a different function of the packaging process via robotics, while its Transmodul single-axis transport robot runs on a rail system that passes through all the sub-machines. At each end of the rail section, a turning unit on the Transmodul enables unloaded modules to travel back to the other end on the lower track. To hold items in place during transport, the Transmodul is equipped with a vacuum blower. Data and signals are transmitted wirelessly.

The decision by Kühne to purchase two new lines was driven by the different performance levels of the upstream filling stations. The first line packs two sizes of remoulade jars, while the second handles six formats of the company’s Made for Meat barbecue sauces and its vinaigrette salad dressings, packed in round glass bottles. On both lines, the packaging process takes place in counterflow.

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