Streamlining Production: Jug Packaging and Palletizing Project
Re-Designing for Scale
The facility’s original setup was designed for a one-part flow, which capped output and slowed production. Our team re-designed and re-tooled the system so it could handle up to 12 jugs at a time; a significant leap in throughput.
A key part of the upgrade was developing a custom end-of-arm tool for the jug boxing robot. This new tool allows the robot to pick up multiple jugs at once, increasing speed while maintaining the precision that robotics integration requires.
Smarter Palletizing Automation
To eliminate downtime, we introduced a multi-zoned palletizing system. With this change, production keeps running even when one pallet is full or when slip sheets need to be added. This adjustment reduced bottlenecks and allowed for a smoother, more continuous product flow; a perfect example of how palletizing automation can boost productivity.
Safety Comes First
No automation upgrade is complete without a focus on safety. To bring the system up to modern standards, we integrated:
An Omron safety PLC
Fanuc DCS (Dual Check Safety) for robotic operations
Light curtain guarding for pallet zones
These safety features ensure the system runs efficiently while protecting operators on the floor.
Advanced Control Systems and Product Flow
We also designed a new control system featuring an Omron PLC, networked I/O, and a responsive Omron HMI screen for intuitive operation.
To further streamline the process, our team engineered custom product flow mechanisms to separate and orient jugs before robotic pick-up. Coupled with Fanuc robot integration, this ensures reliable, repeatable motion across the line.
Designed, Built, and Tested by TFA Solutions
Every element of this automation solution was designed, manufactured, and assembled in-house at our London, Ontario facility. Using 3D CAD software, we achieved highly accurate design and build standards. And as always, our work didn’t stop at delivery, our team supported installation, startup, and testing on-site to make sure everything ran as intended.
The Result
The re-imagined jug packaging and palletizing system shows what TFA Solutions does best: deliver end-to-end automation solutions that bring together robotics integration, PLC programming services, palletizing automation, and control systems engineering.
The result for the customer? A line that is faster, safer, and ready to scale with their production needs.
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TFA Solutions
Design | Build | Automate
📍 London, Ontario | Your partner for industrial automation in Southwestern Ontario