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Eggcelent factory performance with robotic automation

 

Kawasaki Robotics contributes greatly to automation flexibility at egg factories worldwide

  • Freeing up workers for quality promoting work
  • Ensuring consistency in throughput and higher yield
  • Increased production capacity
  • Increased competitiveness

SANOVO TECHNOLOGY GROUP is a market leader in the egg processing industry. For more than 60 years, SANOVO TECHNOLOGY GROUP has been a key player in the egg industry and positioned itself as a global supplier of technological solutions across business industries – and Kawasaki Robots have become an important factor in their product portfolio. 

 

Kawasaki: Eggceptional automation solution

In a modern egg factory, you can almost avoid manual operations by automating the time-consuming elements of the production. Thereby removing the everyday, mundane tasks at factories worldwide, and freeing up workers for quality promoting work.

SANOVO TECHNOLOGY GROUP's robotic automation program offers several efficient and flexible solutions that are a vital part of any modern egg handling and processing factory. However, robotic automation is not only a question of reducing labour. It relates just as much to increasing biosecurity, product quality, and maximizing the yield – and at the centre of their robotic automation solutions are robots from Kawasaki.

Equipped with robot arms, SANOVO TECHNOLOGY GROUP's solutions solve everything from palletizing and de-palletizing to case packing and display loading with high precision and speed. The gripping tool has been developed to be able to support high flexibility in handling different case types and various assignments depending on the need.

“The installation of Kawasaki Robots in our solutions has been an essential factor in increasing production capacity and ensuring competitiveness for our customers,” says Philip Sejling Kogut, Product and Business Manager at SANOVO TECHNOLOGY GROUP. “The flexibility and efficiency of robotic automation is a vital part of any modern egg handling factory. Automation provides more consistency in the throughput and helps achieve higher yields. Furthermore, it contributes to ensuring high-quality standards in egg production.”

 

Flexible robotics for any need

One of the great things about Kawasaki robots is their versatility and flexibility. Kawasaki industrial robots have high-performance technological features, amplified by the power of the controllers and software that can be customized for every industrial automation need.

The high degree of versatility is something SANOVO TECHNOLOGY GROUP benefits greatly from. At the moment, they use four different robots in their solutions depending on the task. 

  • For case packing in the US, two RS005 robots help pack 30 egg trays into cardboard boxes. The Kawasaki Robots enable the case packing solution to handle up to 160 cases/hour or 57,600 eggs/hour. The RS005 model is one of the smallest R series robots, making it ideal for small-scale material handling applications requiring low payload. 
  • Case packing is not a one-size-fits-all task. That is why SANOVO TECHNOLOGY GROUP also use the RS007 robot for case packing of packages of different sizes into different types of boxes. The RS007 is easy to adopt for assembly, pick and place, packaging and more. Another great functionality of RS007 is the overdrive functionality meaning the robot can be programmed to move at speeds up the 3x of normal when not carrying a payload. When cycle times are counted in seconds, this is a huge advantage.
  • In their de-palletizing machines and egg palletizing solutions, they use the ZX165 robot. The de-palletizing machine gently handles plastic trays of up to 600 cases/hour (216,00 eggs/hour). Known as the workhorses of the Kawasaki Robotics product line, the ZX series is suitable for a variety of applications from assembly to material handling. The ZX series is suitable for harsh environments and can manage a payload of up to 300 kg.
  • Designed specifically for palletizing, CP300 is ideal for palletizing boxes. The case palletizing robot can palletize at a speed of 600 cases/hour (216,000 eggs/hour). The CP series feature industry-leading cycle times, a broad motion range, a space and energy-saving controller, and easy-to-use palletizing software to program the operation.

DAVA Foods eggcellerated their production capacity

One of the companies benefitting from SANOVO TECHNOLOGY GROUP's innovative solutions is DAVA Foods Denmark; a company that runs an egg packing station where they pack 1,5 to 2,0 million eggs per day. Due to a goal of increasing their production and competitiveness, DAVA Foods implemented an automation solution with several Kawasaki Robots aiding their goal. The intention of this implementation was to increase the production capacity, which was unachievable without the precision and speed of e.g., an RS007 robot that helps meet their ambitious goal of 250.000 eggs an hour, which is maximum capacity.

DAVA Foods needed to optimize their production chain to keep meeting demand,” says Philip Sejling Kogut, Product and Business Manager at SANOVO TECHNOLOGY GROUP. The installation of the robot unit did not affect production and has since increased the overall output and quality of the egg production at DAVA Foods.

Labour shortage and a better work environment

The Kawasaki robots also help solve the issue of labour shortage that a lot of countries and industries are currently experiencing. Hiring enough hands to cover production lines is a near-impossible job. This is also true for the egg industry. The high demand for workers in the industry often leads to production lines that are severely understaffed.

Moreover, repetitive movements and lifts can have long-term effects on workers, who have their daily dealings in factories. The implementation of Kawasaki Robots means a reduction in monotone tasks, which thereby decreases the physical handling of heavy boxes that can lead to injuries and long-term health conditions. This means that the tasks now handled by the Kawasaki robot free up workers, who instead can handle other value-adding tasks or strengthen their skills in other areas.

 

Increased traceability and quality of the eggs

Another aspect of the implementation at DAVA Foods has been the additional focus on quality. With the new unit in their production chain, DAVA Foods can detect, e.g., cracks or blood in the eggs.

In addition to an increase in output capacity and eliminating the issue of labour shortage, the Kawasaki robots optimise traceability. A Kawasaki robot de-palletizes the pallet of eggs, so the process of replacing one egg with an RFID egg is much easier. We also add traceability to count and organize documents in the CRM and financially make a more precise quality control of eggs from the farm.

The Kawasaki robots at DAVA Foods are implemented in units in the production chain, which improve efficiency, competitiveness, quality, and the general workplace environment. The installation is usually quick to keep production interference to a minimum. 

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