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Advanced beverage packaging at Brewery Gebr. Maisel: Profipack integrates Stäubli technology for full automation

 

“Thanks to the automatic tool changing system from Stäubli, we were able to significantly reduce setup times and relieve our employees from having to lift heavy tools. At the same time, we achieved higher output performance. This makes us more capable of delivering and allows us to respond more quickly to changes in the market.”

Andreas Müller,
Head of Control and Planning Brewing Operations,
Brewery Gebr. Maisel GmbH & Co. KG

The partners

Profipack Verpackungsmaschinen GmbH, a leading provider of intelligent packaging and intralogistics solutions, develops tailor-made automation systems to enhance performance and flexibility. With strong expertise in robotics, palletizing and conveyor technologies, the company delivers high-performance turnkey solutions for complex industrial environments.

Among its customers, the renowned German brewery Gebr. Maisel GmbH & Co. KG relies on Profipack’s expertise to optimize its production operations. In a demanding environment where hygiene, reliability and process continuity are critical, the brewery requires robust and efficient solutions.

By combining engineering excellence with a deep understanding of industrial challenges, Profipack helps Maisel build a highly efficient, future-ready production environment, leveraging advanced technologies from trusted partners such as Stäubli.

The application

At the core of the project is a fully automated packaging line designed to optimize end-of-line operations. Bottles are automatically removed from crates and repacked into 4‑ to 6‑packs or into 20‑unit cartons for international export, enabling flexible production of both standard and promotional formats.

Another robot then takes over carton loading and palletizing, ensuring a seamless, continuous flow from raw product handling to fully prepared pallets ready for shipment.

When growing production demands challenge packaging performance

Maisel’s needed to upgrade its packaging operations to meet increasing production demands while maintaining high quality standards. The key challenges included:

  • Efficient handling of returnable crates within internal logistics
  • Managing multiple packaging formats, including 4 or 6-packs and cartons
  • Reducing manual handling in a high-speed production environment
  • Ensuring continuous operation with maximum reliability

The project required Profipack to design a complex, high-performance automation system capable of meeting demanding requirements:

  • Developing a fully integrated end-of-line solution
  • Coordinating multiple robotic systems in a continuous flow
  • Managing transitions between crates, loose bottles, and packaged goods
  • Delivering flexibility for evolving production needs
  • Meeting strict targets in terms of speed, uptime and reliability

A flexible automation system built for high-performance packaging

Profipack implemented a fully automated packaging system combining robotic handling and optimized product flow. Multiple robotic cells ensure continuous operation from crate handling to final palletizing.

The system integrates Stäubli robotic tool changer systems (MPS) directly at the robot interface. Three robots with a total of 12 tool variants within the production line enable flexible handling of different bottle shapes and packaging units. 

Driving performance for both end-user and integrator

 

For MaiselFor Profipack
  • Increased production efficiency
  • Consistent packaging quality
  • High flexibility for different formats
  • Improved working conditions
  • Optimized internal logistics
  • Demonstration of system integration expertise
  • Reference project in the beverage industry
  • Validation of flexible and scalable solution design
  • Strengthened position as automation partner

Get in touch with our specialist!

Interested in learning how we supported Maisel in this latest success story? Our teams are ready to help you tackle your safety, performance, and operational challenges and explore how similar solutions can drive results for your business.

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Stäubli makes work easy and safe

Interested in learning how we supported our partners in this latest success story? Our teams are ready to help you tackle your safety, performance, and operational challenges and explore how similar solutions can drive results for your business.

Safe and easy‑to‑use

in every process with our MPS solutions

High‑performance

and reliable components developed by Stäubli for robotics applications

Support

for large‑scale deployment of MPS solutions in factories, accelerating the processes

Advanced safety protections

including systems that prevent accidents

Positive user feedback

confirming the reliability and practicality of the system