Food industry Success story

Making short work of crumbly products

Customer benefits
  • Cost-effective, highly productive solution
  • High reliability of the robots despite adverse operating conditions
  • Short cycle times, high output
  • Strict compliance with hygiene requirements
Stäubli AG - robotics-solutions-food-ready-made-meal-success-story-TST-dim-2x-47129-jpg-orig.jpg

TASK

Packaging of fish sticks

The standard pack of 15 breadcrumb-coated fish sticks is a classic in the frozen products range. In order to stay competitive within tight margins, seafood specialist TST opted for automation throughout with Stäubli industrial robots.

TST (The Seafood Traders) is committed to the volume production of fish products at the best possible price. A prerequisite for this is rapid processing, which is no longer conceivable in the food sector without automation. The value chain of the seafood specialist starts with sawing frozen blocks of raw fish and then continues through baking, coating with breadcrumbs and freezing, culminating in the packaging of the finished products.

One particular challenge is the packaging of fish sticks. Even in a frozen state, these natural products with their bread coating are crumbly to the touch and can push any automated system to its limits. For the realization of a robot-based packaging line, TST called on the services of ECONO-PAK in Flonheim, an equipment manufacturer specializing in the primary packaging of foodstuffs.

 

SOLUTION

Criteria only manageable with Stäubli robots

At the planning stage, it soon became apparent that a linear system with a sideload cartoning machine would be the right way to optimize the cycle times for getting the finished products packed in boxes. The sorting and grouping of fish sticks beforehand was to be handled by six-axis robots. However, the specified capacity of five tonnes of fish per hour and per packaging line proved to be an impossible challenge for almost all of the robot manufacturers consulted. Only Stäubli Robotics was able to guarantee that its high-speed six-axis robots (Type TX90L) working in shifts around the clock would be up to the task.

The Stäubli TX90L HE also scores top marks for its enclosed construction with internal cabling and the fact that it has been specifically designed for humid environments (hence the HE suffix). It therefore does not require any additional protective cover to comply with the strict hygiene regulations in the food industry and with all the other requirements for use in direct contact with frozen products. Four Stäubli TX90L HE robots work in concert on each of the two packaging lines for high-grade fillets and fish sticks. They form the core of the automated systems, assuming responsibility for grouping prior to packaging – five gourmet fish fillets or 15 fish sticks depending on the line. Each robot handles the contents of one package, and does so 50 times per minute.

The robots are tasked with moving the fish sticks in batches of 15 off the four belts onto a centrally located product cassette belt which leads to the packaging station. The four robots are capable of shif