Packaging line for frozen ciabatta bread

Packaging line for frozen ciabatta bread

In a competitive industry such as industrial baking, automation has become a key factor in increasing efficiency and maintaining product quality. This was precisely the starting point for a well-known Spanish company specializing in frozen bread and pastries, which faced a significant obstacle in one of its plants: the packaging line for pre-cooked and frozen ciabatta bread.

Línea automatizada de envasado de chapatas congeladas con robots y visión artificial

The challenge: A robotic line for packaging ciabatta bread

After an unsatisfactory experience with a previously purchased automated machine, the company had decided to return to the manual process of packaging ciabatta bread in packs of four, which limited their production capacity, increased operating costs, and reduced product traceability. In addition, the packaging process had to be integrated with the existing case packing system without compromising the visual quality control previously performed by the operators. In this context, the challenge was to design a robust, flexible, and precise solution that would unify all stages of the process – from product receipt, through pick & place, flowpack packaging and case packing – in one area and under one system. In addition, human visual quality control was required before products entered the robotic cell. With the bread arriving at high speed, over 230 units per minute, in a single-file sequence, it was critical to slow down the flow to allow personnel to adequately inspect and detect faulty batches.

The solution: A picking line with artificial vision

The result was a picking line with artificial vision that not only solved the issues of the previous system, but also added value by providing a more efficient, safe, and controlled operation.

We implemented a modular robotic cell equipped with an advanced artificial vision system, capable of detecting and automatically picking up the ciabatta bread as it arrived from the production line. The bread was then placed directly onto the fixed chain conveyor of a flowpack machine configured to package four-unit packs. The system was further integrated with the client’s clipping and weighing machine to complete the packaging cycle.

To address the speed issue, we developed a multi-lane product diversion system that allowed the linear infeed speed to be reduced without compromising production capacity. This diversion not only facilitated visual inspection by personnel, but also improved product segregation, optimizing robotic picking.

Moreover, the 3D artificial vision system adapts to variations in the height and shape of the ciabatta breads, identifying and rejecting products with significant dimensional deformities before they enter the packaging process.

What did we achieve?

01_

Increased cohesion and operational efficiency by unifying the packaging and case packing processes.

02_

Flexibility and adaptability, thanks to a system that easily adapts to production changes and product variations.

03_

Improved final product quality by detecting defective products prior packaging.

04_

Optimization of resources, both in space usage and personnel.

This project is a clear example of how intelligent automation can solve complex challenges in demanding industrial environments. Thanks to the implementation of a robotic picking line with artificial vision, the company not only regained the ability to automate the packaging of ciabatta bread but also exceeded its initial goals in terms of efficiency, quality, and traceability.

The solution developed not only addresses a specific problem but also lays the foundation for future applications in other product lines. Its modularity, adaptability, and efficiency make this implementation a scalable and replicable model within the industrial bakery sector.