Industrial producers typically battle with capability, labor pressure, and consistency.
At Korea Filter Engineering, guide palletizing of 10–20 kg (22-44 lb) industrial filter packing containers was limiting output, growing ergonomic danger, and slowing deliveries.
After deploying the Robotiq PE20 with a UR20, the corporate achieved:
- 30% manufacturing improve
- 50% discount in employee fatigue
- Close to 50% discount in injury-related absences
- Zero office incidents since set up
- ROI anticipated inside 2 years
This case examine exhibits how collaborative robotic palletizing improves productiveness whereas defending employees in heavy-load manufacturing environments.
Firm overview: Industrial filter manufacturing in South Korea
Based in 1996 and primarily based in Gimpo, Korea Filter Engineering manufactures industrial filters utilized in electrical discharge machining (EDM).
- Business: Industrial filter manufacturing
- Workers: 15
- Each day palletizing load (earlier than automation): ~4 tons
- Field weight: 10–20 kg
With a lean workforce and rising demand, guide palletizing turned a manufacturing bottleneck.
The problem: Handbook palletizing of heavy packing containers
Earlier than automation, employees manually lifted and stacked roughly 4 tons of product per day.
Key points included:
1. Ergonomic danger and employee fatigue
- Repetitive lifting of 20 kg packing containers
- Again, shoulder, and muscle pressure
- Growing older workforce growing damage danger
- Fatigue affecting morale and consistency
2. Productiveness limitations
- Each day output capped at 200 packing containers
- Delays brought on by bodily pressure and absenteeism
- Issue sustaining constant throughput
3. Failed options
Earlier lifting aids have been examined however operations repeatedly reverted to completely guide palletizing on account of complexity or inefficiency.
The corporate wanted an answer that was:
- Compact
- Steady
- Simple to function
- Secure for human-robot collaboration
- Fast to deploy
The answer: Robotiq Lean Palletizing
In early 2025, Korea Filter Engineering chosen the Robotiq PE20 palletizer built-in with the UR20 collaborative robotic.
Why this palletizing system?
- Handles packing containers as much as 20 kg
- Helps as much as 20 SKUs
- Most pallet peak: 2130 mm (84 in)
- Compact footprint for space-constrained services
- Works alongside workers with out in depth security fencing
- Intuitive interface requiring minimal coaching
Quick deployment timeline
- Early 2025: Analysis
- March 2025: Citation
- Might 2025: Set up and launch
Minimal format modifications have been required. The system built-in seamlessly with the prevailing conveyor.
Operators have been in a position to be taught and run the system inside minutes, lowering dependency on specialised robotics experience.
Outcomes: Measurable features in productiveness and security
1. 30% manufacturing improve
- Output elevated from 200 to 250 packing containers per day
- Increased throughput with out growing headcount
- Improved supply reliability
2. Improved employee well being and security
- Harm-related absences almost halved
- Employee fatigue diminished by greater than 50%
- Zero office incidents since set up
Younger-Hun Yoo, Assistant Supervisor in Manufacturing, shared:
“After utilizing the robotic, our our bodies are more healthy, and we really feel much less drained—lower than half in comparison with earlier than. We’ve extra power left for our households after work.”
3. Workforce optimization
- One full-time worker reassigned to higher-value duties
- Much less bodily pressure, extra operational focus
- Stronger staff morale
4. Robust monetary case
- Anticipated return on funding inside 2 years
- Lowered oblique prices associated to damage and absenteeism
- Elevated capability with out increasing facility house
Why collaborative robotic palletizing works in heavy manufacturing
This venture demonstrates key benefits of cobot palletizing methods:
Protects employees from repetitive heavy lifting
Eradicating 4 tons of day by day guide lifting dramatically reduces ergonomic danger.
Will increase output with out increasing workforce
Automation dietary supplements labor as an alternative of changing it.
Scales with product variability
The PE20 handles as much as 20 SKUs, supporting various product traces.
Suits in space-constrained services
Compact design makes it viable for small and mid-sized producers.
Permits quick ROI
Measurable productiveness and security enhancements speed up payback.
Woo-Seok Kim, Director of Enterprise, defined the choice:
“We checked many robotic methods, however the PE20 was probably the most secure. Defending our employees is an important factor, and the PE20 permits us to try this. That’s the reason it’s well worth the funding.”
Key takeaways for producers contemplating automation
In case your operation includes:
- Handbook palletizing of heavy packing containers
- Repetitive lifting inflicting fatigue or accidents
- Labor shortages or getting older workforce challenges
- Restricted flooring house
- Productiveness plateaus on account of bodily constraints
Collaborative palletizing automation could ship fast, measurable affect.
Korea Filter Engineering’s transformation proves that producers do not need to decide on between:
- Productiveness and security
- Progress and workforce wellbeing
- Automation and operational stability
With the proper palletizing answer, you possibly can obtain all three.
Is Lean Palletizing the proper match to your manufacturing line?
Use Robotiq’s Palletizing Match Device to shortly assess whether or not cobot palletizing is smart to your operation and what a practical deployment might appear to be to your facility. You may even get personalised estimates for ROI and payback durations and a 3D simulation of what Lean Palletizing might appear to be in your manufacturing unit flooring.
