STAUBLI

Now is the time to unleash the potential for robotics in UK food manufacture

There are few who would argue that 2020 has been an extremely challenging year as the COVID-19 pandemic has changed the way in which businesses of all types operate and more importantly, the environment within which we work, as we strive to contain the virus and remain safe. As businesses adapt to what is likely to be the new “normal” for the forseeable future at least, and with the ongoing uncertainty surrounding the effects that Brexit may have as we near the end of the transition period, the debate surrounding robotics and automation, especially within the food manufacturing and processing sector, is reaching a new peak.

It is becoming clear that robotics and automation will hold the key to achieving the efficiency and productivity levels required for cost effective food processing, especially in high-care areas, and those which traditionally have been labour intensive. This article by Simon Jenkins of Stäubli explains why now is the perfect time for the UK food manufacturing sector to unleash the potential that robotics holds, and how companies will benefit, not only in addressing the short term issues within the sector, but in securing their future.

There is no doubt that historically people have been the highly flexible resource which has sustained manufacturing in many sectors, including food and beverage. The ability of humans to adapt to changes in products and processes is, even today, unparalleled in some cases. However, the demands for greater quality, consistency and predictable high productivity levels, combined with 50 FDPP - www.fdpp.co.uk

a growing shortage of manual resource, have been the drivers for increased levels of robotics and automation within the food sector in recent times.

The COVID-19 pandemic has also raised the stakes for the adoption of robotics and automation as a means of removing people from what are now being seen as the high risk environments within a range of manufacturing environments, including meat processing facilities. Large numbers of people working within a chilled and sometimes confined environment have proven to be a catalyst for rapid transmission of this deadly virus.

Stäubli’s Simon Jenkins explains further: “The food and beverage sector is currently facing serious issues brought about by difficulty in recruitment and retention, the significant challenges surrounding COVID-19 and future uncertainty around the UK outside of the European Union next year. Although many of the potential benefits of robotics and automation, when applied to food manufacturing, have been understood for some time, there has still been a reluctance overall to fully embrace the technology. The often perceived barriers to automating food manufacturing processes, those of limited flexibility, complexity and unsuitability for high care areas, are no longer valid with the latest generation robot systems. Many of the challenges now being realised in high care areas, such as meat processing, can be addressed successfully using the HE series robots, specifically designed in conjunction with (EHEDG) - The European Hygienic Engineering & Design Group and their guidelines.”

An innovative solution for processing pork and removing bones from pork legs can be seen in this Japanese system, which incorporates three Stäubli sixaxis RX160 HE robots operating as master butchers. The specifications for robotics in a meat factory could not be more onerous. Chief among them are the strict hygiene requirements that apply to the handling of fresh meat. In addition, expectations in terms of speed, precision and flexibility are set high, as no fewer than 500 pork legs enter and leave the line each hour. The functionality of the robots operating within this system are at the highest levels possible, given the special conditions prevailing in the meat processing industry. Also, because no one piece of pork is the same as another, flexibility is required to allow high-speed processing

Simon Jenkins expands on the capabilities of this system: “This system clearly demonstrates what the latest generation technologies are capable of and therefore what can be achieved here in the UK. In this application, an X-ray system is used to detect the position of the bones within the meat, and the exact incision line for the robots is then calculated. A perfect solution, but one that is also subject to the vagaries of the meat processing industry. The fact that the meat hanging on its hook is liable to shift its position on the overhead conveyor within certain limits means that the robots must operate in a highly coordinated way to achieve the correct cut and avoid the bones.”

The de-boning system represents a high level application of robots within the food sector, however there are also many other less complex applications, such as handling and packing products, where robots can be used to address the numerous issues facing the UK’s food manufacturers.

Of course, this will require investment by manufacturers, and historically the traditional short term view on payback on capital projects is often cited as a reason to avoid investing in new equipment or technology such as robotics or automation. Taking an alternative view, either on the duration of the payback period and / or considering flexible financing options such as hire or leasing, may open the door to the introduction of the technology which could potentially transform productivity levels.

Improvements as a result of this investment may actually contribute to the security of contracts with customers and ultimately the long term future of the business. The flexibility of robots, for example, allows them to be used for new products or new contracts and their inherent reliability means that they will provide years of service. Having this type of technology in place when bidding for new contracts can also differentiate suppliers and provide a competitive advantage.

www.staubli.com