Industrial producers typically wrestle with capability, labor pressure, and consistency.
At Korea Filter Engineering, guide palletizing of 10–20 kg (22-44 lb) industrial filter packing containers was limiting output, growing ergonomic danger, and slowing deliveries.
After deploying the Robotiq PE20 with a UR20, the corporate achieved:
- 30% manufacturing improve
- 50% discount in employee fatigue
- Close to 50% discount in injury-related absences
- Zero office incidents since set up
- ROI anticipated inside 2 years
This case examine exhibits how collaborative robotic palletizing improves productiveness whereas defending employees in heavy-load manufacturing environments.
Firm overview: Industrial filter manufacturing in South Korea
Based in 1996 and primarily based in Gimpo, Korea Filter Engineering manufactures industrial filters utilized in electrical discharge machining (EDM).
- Trade: Industrial filter manufacturing
- Workers: 15
- Day by day palletizing load (earlier than automation): ~4 tons
- Field weight: 10–20 kg
With a lean workforce and rising demand, guide palletizing turned a manufacturing bottleneck.
The problem: Guide palletizing of heavy packing containers
Earlier than automation, employees manually lifted and stacked roughly 4 tons of product per day.
Key points included:
1. Ergonomic danger and employee fatigue
- Repetitive lifting of 20 kg packing containers
- Again, shoulder, and muscle pressure
- Growing old workforce growing damage danger
- Fatigue affecting morale and consistency
2. Productiveness limitations
- Day by day output capped at 200 packing containers
- Delays brought on by bodily pressure and absenteeism
- Problem sustaining constant throughput
3. Failed options
Earlier lifting aids have been examined however operations repeatedly reverted to totally guide palletizing resulting from complexity or inefficiency.
The corporate wanted an answer that was:
- Compact
- Secure
- Simple to function
- Secure for human-robot collaboration
- Fast to deploy
The answer: Robotiq Lean Palletizing
In early 2025, Korea Filter Engineering chosen the Robotiq PE20 palletizer built-in with the UR20 collaborative robotic.
Why this palletizing system?
- Handles packing containers as much as 20 kg
- Helps as much as 20 SKUs
- Most pallet peak: 2130 mm (84 in)
- Compact footprint for space-constrained services
- Works alongside workers with out intensive security fencing
- Intuitive interface requiring minimal coaching
Quick deployment timeline
- Early 2025: Analysis
- March 2025: Citation
- Might 2025: Set up and launch
Minimal format modifications have been required. The system built-in seamlessly with the prevailing conveyor.
Operators have been capable of be taught and run the system inside minutes, decreasing dependency on specialised robotics experience.
Outcomes: Measurable positive factors in productiveness and security
1. 30% manufacturing improve
- Output elevated from 200 to 250 packing containers per day
- Greater throughput with out growing headcount
- Improved supply reliability
2. Improved employee well being and security
- Damage-related absences almost halved
- Employee fatigue diminished by greater than 50%
- Zero office incidents since set up
Younger-Hun Yoo, Assistant Supervisor in Manufacturing, shared:
“After utilizing the robotic, our our bodies are more healthy, and we really feel much less drained—lower than half in comparison with earlier than. We have now extra vitality left for our households after work.”
3. Workforce optimization
- One full-time worker reassigned to higher-value duties
- Much less bodily pressure, extra operational focus
- Stronger crew morale
4. Sturdy monetary case
- Anticipated return on funding inside 2 years
- Diminished oblique prices associated to damage and absenteeism
- Elevated capability with out increasing facility area
Why collaborative robotic palletizing works in heavy manufacturing
This challenge demonstrates key benefits of cobot palletizing methods:
Protects employees from repetitive heavy lifting
Eradicating 4 tons of each day guide lifting dramatically reduces ergonomic danger.
Will increase output with out increasing workforce
Automation dietary supplements labor as a substitute of changing it.
Scales with product variability
The PE20 handles as much as 20 SKUs, supporting numerous product traces.
Suits in space-constrained services
Compact design makes it viable for small and mid-sized producers.
Permits quick ROI
Measurable productiveness and security enhancements speed up payback.
Woo-Seok Kim, Director of Enterprise, defined the choice:
“We checked many robotic methods, however the PE20 was probably the most steady. Defending our employees is crucial factor, and the PE20 permits us to do this. That’s the reason it’s definitely worth the funding.”
Key takeaways for producers contemplating automation
In case your operation includes:
- Guide palletizing of heavy packing containers
- Repetitive lifting inflicting fatigue or accidents
- Labor shortages or ageing workforce challenges
- Restricted ground area
- Productiveness plateaus resulting from bodily constraints
Collaborative palletizing automation might ship fast, measurable affect.
Korea Filter Engineering’s transformation proves that producers should not have to decide on between:
- Productiveness and security
- Development and workforce wellbeing
- Automation and operational stability
With the proper palletizing resolution, you’ll be able to obtain all three.
Is Lean Palletizing the proper match in your manufacturing line?
Use Robotiq’s Palletizing Match Instrument to rapidly assess whether or not cobot palletizing is smart in your operation and what a sensible deployment may appear like in your facility. You may even get personalised estimates for ROI and payback intervals and a 3D simulation of what Lean Palletizing may appear like in your manufacturing unit ground.
