Robust Robotic Tray Handling Solution for a Leading FMCG Company

Background

A leading FMCG company required a special purpose machine for robotic tray handling of hot baked trays. The application involved picking up heated trays from one robotic station and delivering them to a conveyor system, which would then transfer them through several processes before reaching the next robotic system. At this stage, empty trays were also picked up and cycled back into production.

Challenge

The customer was facing serious operational issues with one of its existing lines supplied by a vendor:

– Line not suitable for heavy-duty operation – The system design lacked robustness, leading to frequent breakdowns.
– Tray inconsistencies – Due to the heating and cooling process, trays were not dimensionally consistent, creating significant handling difficulties.
– Unreliable performance – The line could not sustain the required duty cycle, resulting in frequent stoppages and reduced productivity.

This directly impacted the company’s ability to maintain smooth operations and overall production efficiency.

Alligator Automation’s Approach

Alligator Automation worked closely with the customer to thoroughly understand the process, the tray handling requirements, and the operational pain points. The team carried out:

– Detailed product study – Analyzing the behavior of trays under varying temperatures and process conditions.
– System redesign – Engineering a heavy-duty, robust system capable of withstanding continuous operations while compensating for dimensional variances in trays.
– Innovation – Developing a unique mechanism within the machine, for which Alligator Automation has applied for a patent.

Solution Delivered

– Designed and deployed a pilot system with enhanced durability and tolerance handling.
– Stabilized the pilot successfully at the customer’s site.
– Demonstrated consistent performance under heavy-duty operation.

Results & Impact

– Customer Confidence – The successful pilot led to repeat orders.
– Scalability – The company placed back-to-back orders for more than 8 lines of the same solution.
– Reliability – Ensured high life, high duty cycle operation with robust engineering.
– Customer Delight – The solution effectively addressed the operational pain points, restoring reliability to the production line.

Conclusion

This case study highlights how Alligator Automation’s engineering excellence, customer-first approach, and innovative design enabled a leading FMCG manufacturer to overcome major production challenges. By addressing the root cause with a tailored, robust robotic tray handling solution, Alligator not only solved an immediate problem but also built long-term trust with a global brand.