Line 32 Robotic Depalletizing & Palletizing Cell Modernization
A Top Tier Food Manufacturer's Line 32 couldn't keep pace with demand — downtime between depalletizing and palletizing, plus consistent downtime inside both cells, was stacking losses on every shift. J+H Automation Solutions designed and built new end-of-arm tooling for the customer-supplied Yaskawa robots, reprogrammed both robot cells for faster, more reliable cycles, and engineered a new cell layout — delivering a modern end-of-line system targeting a 1–1.5 year return on investment from improved throughput alone.
The Challenge & the J+H Solution
The Top Tier Food Manufacturer faced two compounding problems on Line 32: throughput lagging behind demand due to downtime between the depalletizing and palletizing of product, and consistent downtime within both cells that multiplied the losses. The plant needed real gains in uptime and cycle speed — without replacing the robots it already owned.
The Challenge
- Line 32 throughput could not keep pace with production demand
- Downtime between depalletizing and palletizing created a persistent bottleneck
- Consistent downtime within both robot cells compounded the losses
- Existing EOAT and cell programming limited cycle performance
- The layout complicated flow between cells and operator access
The J+H Solution
- New end-of-arm tooling designed and built for the customer-supplied Yaskawa robots
- Robot cells reprogrammed for improved, cycle-optimized performance
- New cell layout designed and built to eliminate the between-cell bottleneck
- Integrated conveyance with CDLR conveyor and blade stops for positive case control
- Consolidated safety architecture on a Compact Logix Safety Processor with PanelView Plus HMI
How the Modernized End-of-Line Runs
From inbound pallets to finished outbound loads, the rebuilt Line 32 moves product through three coordinated stages engineered as a single system.
Robotic Depalletizing
A vacuum side-pick EOAT built around venturi vacuum generation lifts layers cleanly from inbound pallets — engineered for reliable pickup, fewer faults, and fewer operator cell entries.
Controlled Conveyance
Cases move between cells on CDLR conveyor with blade stops for positive positioning, closing the downtime gap that once separated depalletizing from palletizing.
Robotic Palletizing
A new palletizing EOAT with pneumatic clamping, slip-sheet pickup, and replaceable machined fingers builds outbound pallets at a 30 cases-per-minute takt — averaging 5 cases per pick on a 10-second cycle.
What J+H Designed, Built & Integrated
Every element was engineered, fabricated, and factory acceptance tested (FAT) before shipment — then installed and commissioned as one integrated cell.
Custom EOAT for Customer-Supplied Robots
Two new end-of-arm tools purpose-built for the plant's existing Yaskawa robots: a vacuum side-pick depalletizing tool and a palletizing tool with pneumatic clamping, slip-sheet pickup, and replaceable machined fingers that keep maintenance fast and inexpensive.
Robot Cell Reprogramming
Both cells were reprogrammed for cycle-optimized motion — hitting the 30 cases-per-minute takt with the robot running at only 75% of maximum speed, leaving real headroom for future demand growth.
New Cell Layout Design & Build
A redesigned layout that eliminates the throughput-killing gap between depalletizing and palletizing, improves product flow, and simplifies operator and maintenance access to both cells.
Controls & Safety Modernization
A consolidated safety architecture on an Allen-Bradley Compact Logix Safety Processor with PanelView Plus HMI — replacing fragmented legacy safety systems with one modern, maintainable platform.
Results That Pay for Themselves
The project's return was justified on throughput alone.
Measured Performance
- 30 cases per minute takt time across the integrated end-of-line
- 10-second average pick-and-place cycle handling 5 cases per pick
- Robot speed capped at 75% of maximum — built-in capacity headroom
- 95% OEE target enabled by the new cell design and programming
Business Impact
- 1–1.5 year targeted ROI based solely on improved throughput and increased outgoing product
- Reduced maintenance burden through replaceable machined tooling components
- Fewer cell entries and faults from reliable, purpose-built EOAT
- Simplified safety compliance on a single consolidated safety platform
Built for Food & Beverage Manufacturing — and Beyond
This project reflects the end-of-line automation J+H delivers for food & beverage manufacturers across the United States: robotic depalletizing and palletizing cells, custom EOAT, conveyance, and consolidated safety controls engineered to raise throughput without replacing the equipment plants already own.
The same capabilities — robotic cell design, reprogramming, and integration — extend across J+H's full robotics & AGV solutions, serving manufacturers nationwide from facilities in Hackett, Arkansas and Hockley, Texas.
Frequently Asked Questions
What problem did this depalletizing and palletizing project solve?
Throughput on Line 32 could not keep pace with demand because of downtime between the depalletizing and palletizing of product, compounded by consistent downtime within both cells that stacked losses on top of already slower-than-needed run rates. J+H eliminated the bottleneck with new end-of-arm tooling, reprogrammed robot cells, and a redesigned cell layout.
Can J+H build new EOAT for a robot we already own?
Yes. On this project, J+H designed and built new end-of-arm tooling for the customer-supplied Yaskawa robots — a vacuum side-pick depalletizing tool and a palletizing tool with pneumatic clamping, slip-sheet pickup, and replaceable machined fingers — engineered specifically to improve uptime and cycle performance on existing robot hardware.
What throughput did the modernized cells achieve?
The cells run a 30 cases per minute takt time, averaging a 10-second pick-and-place cycle handling 5 cases per pick — with the robot running at only 75% of maximum speed, leaving headroom for future demand. The new cell design and robotic programming target 95% OEE.
What was the return on investment for this project?
The project targeted a 1 to 1.5 year ROI based solely on improved throughput and the increase in outgoing product — before accounting for reduced maintenance burden, fewer cell entries, and simplified safety compliance from the consolidated safety architecture.
Does J+H Automation Solutions build robotic palletizing systems for food and beverage plants?
Yes. J+H Automation Solutions designs, builds, and integrates robotic depalletizing and palletizing cells, EOAT, conveyors, and safety controls for food & beverage manufacturers nationwide from facilities in Hackett, Arkansas and Hockley, Texas — with factory acceptance testing performed before shipment. Contact sales@jhautomationsolutions.com or call (479) 638-8398 to discuss your application.
Is Your End-of-Line Holding Back Throughput?
From new EOAT and robot reprogramming to complete depalletizing and palletizing cell rebuilds, J+H Automation Solutions engineers automation built around your product, your takt time, and your ROI target.
Request a Consultation Call (479) 638-8398