Robotic Case Packer Boosts Uptime to 99 Percent
The new system eliminates manual packing and reduces product changeover times by 40 minutes, boosting efficiency.
Updated on Oct. 29, 2026 in Robotics
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DCC Automation has installed a new robotic case packer for a nutrition supplement manufacturer, resulting in significant operational efficiency gains. The system, which has now shipped and is currently in operation, replaces a legacy semi-automated setup.
Why it matters
The upgrade demonstrates how modern robotic integration can eliminate manual packing labor and resolve end-of-life equipment bottlenecks. By shifting to high-uptime automation, manufacturers can reduce downtime and achieve tighter production throughput targets.
The new case packer delivers 99 to 99.5 percent uptime, vastly outperforming the legacy system's 10 percent downtime per shift. Changeover time has dropped to five minutes, a sharp reduction from the 40 to 45 minutes required previously.
The players
DCC Automation
An industrial automation firm that specializes in designing and integrating robotic packing and material handling systems.
The details
The system architecture uses two-dimensional delta robots—high-speed pick-and-place robots—to manage complete pack patterns. DCC Automation separated the case erector from the packing unit to provide space for product accumulation. Control is handled by Allen-Bradley Compact GuardLogix controllers and Kinetix servo drives, with monitoring managed via FactoryTalk View HMI software over an EtherNet/IP network.
Timeline
October 2026: Official publication of the installation report.
The Tech Race
This installation represents the ongoing industry shift toward replacing aging, pneumatic-heavy equipment with integrated, servo-driven robotic lines. The project follows the broader manufacturing trend of adopting recipe-driven automation to minimize changeover requirements.
This automation upgrade eliminates the need for manual packing previously handled by two or three workers per shift. The shift to a five-minute changeover process allows the manufacturer to increase throughput to meet the required 25 cases per minute threshold.
The takeaway
Manufacturing facilities can look toward the upcoming migration from pneumatic operations to servo-driven technology to further improve efficiency. Tracking successful case packer deployments provides a benchmark for plants facing end-of-life equipment constraints.
Further reading
Learn more about the latest developments in Robotics.
Source note: This article includes information reported by Instrumentation.
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