MIXING, WEIGHING & CONVEYING
DRIVING FLEXIBILITY TO MEET GROWTH
Endoline Robotics replaces a legacy palletising system with flexible high-speed automation at a leading UK flour mill
A
leading UK flour mill has strengthened its automation strategy with the installation of a new high-speed robotic palletising and conveyor solution from Endoline
Robotics, replacing an older system that could no longer meet the business’s growing demands for flexibility and throughput.
Capable of handling up to 14 bundles of flour per minute across two production lines, the equivalent of between 56 and 168 individual bags of flour every minute, the new system is already playing a key role in supporting increased production volumes and future growth. Designed to work alongside an existing Endoline palletiser dedicated to one of the site’s two production lines, the upgrade forms part of a broader automation strategy at the facility. The mill operates two filling lines producing both individual 1–2kg bags and larger 18kg shrink-wrapped bundles. The original system, installed five years ago, manages the individual bags from Line 1. This left Line 2’s individual bags, together with the bundles from both lines, requiring a more flexible palletising solution. Engineered to accommodate both product formats, the system also incorporates the automatic handling and placement of wax paper interlayer sheets. Bundles are conveyed from both lines at speeds of up to 14 per minute per line, equating to a combined throughput of up to 28 bundles per minute. In addition, individual 1–2kg bags from Line 2 are presented at rates of up to 70 bags per minute. The replacement project was driven by the need to overcome limitations within the previous palletising operation, which lacked the flexibility to efficiently handle varying bundle sizes and evolving
product formats. As the mill expanded its product range and customer requirements for bundle sizes became more diverse, a more adaptable solution was required to support continued growth. Combining advanced palletising technology with a fully engineered conveyor network, the system enables both bundled flour products and individual packs to flow seamlessly from packing through to pallet build. By automating what were previously labour-intensive and physically demanding tasks, the flour mill has improved operational efficiency, consistency and working conditions across the site. At the heart of the system is a palletising solution capable of managing product streams from the two filling lines. Bundles and individual packs are transferred via a series of accumulation and transfer conveyors, designed to buffer product flow and maintain a continuous feed into the palletising area without disrupting upstream packing operations. While the palletiser can manage the simultaneous pick-up of bundled products from both lines, it requires a straightforward re-tooling process when switching to palletising individual packs of flour, which are fed down the middle conveyor. This quick-change capability allows the mill to move efficiently between product formats in line with production schedules and changing customer requirements. To minimise downtime during product changeovers, the tooling transition is carried out automatically via the system HMI. The robot docks its current end-of-arm tool, releases it and automatically connects to the alternative tool, ensuring rapid and controlled transitions between bundle and individual pack handling. “Our customer needed a solution that could
replace their existing palletising system with something far more adaptable and capable of
supporting long-term growth,” said Suraj Patel, UK Sales Manager, Endoline Robotics. “By integrating high-speed palletising with a tailored conveyor layout, we’ve delivered a flexible operation that can handle different product formats, varying bundle sizes and increasing volumes.”
While enabling the site to move away from manual-intensive tasks, flexibility has been a central design principle throughout the installation. The modular conveyor layout allows for future expansion and capacity increases, while the palletising system can be easily adapted to accommodate new pack sizes, bundle formats and pallet configurations as the business evolves. “Modern food manufacturers need automation that delivers both performance and adaptability,” Patel adds. “This project shows how replacing legacy systems with flexible technology can improve efficiency today while providing the capacity to grow tomorrow.” Although the latest installation represents a major upgrade, it builds on an established partnership between the two companies. In 2020, Endoline delivered a robotic palletising system at the UK-based mill to support a sharp increase in retail demand during the pandemic. That earlier project helped shape the company’s wider automation strategy and demonstrated the long-term benefits of palletising technology within the milling environment. The palletising and conveyor upgrade provides the flour mill with a future-proof solution that supports current operations while enabling continued growth.
Endoline Automation
www.endoline-robotics.com
14 PROCESS & CONTROL ENGINEERING | MAY 2026
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40
