Packing line for pizzas
According to a recent article in ProFood World, the global frozen pizza market is expected to reach $35 billion by 2033. Manufacturers of frozen pizza have experienced steady sales growth, driven by changes in consumer habits. People are increasingly seeking quick and easy meal options that require minimal preparation time, allowing them to balance work, family, and other obligations.
The article also highlights the sector’s continued growth, noting that manufacturers are diversifying their offerings with new ingredients, dough types, and even vegan options in response to increasingly varied consumer demand. The constant rise in frozen pizza’s popularity is pushing manufacturers to find more efficient ways to increase production capacity to meet the growing global demand and secure the highest possible health and safety standards by minimizing the chances of product contamination.
The challenge: Automation of frozen pizza case packing
The project’s goal was to develop an automated line for packing frozen pizzas into wraparound cardboard cases. The system had to cover the entire process, from forming the cases, loading the products, inserting paper dividers, and sealing the cases.
One of the main challenges was handling fully frozen pizzas with various kinds of toppings. This required an agile process to avoid any risk of defrosting during the packing process.
Additionally, a paper divider had to be placed every two layers of pizzas, which posed a coordination challenge between the robots, product management, and filling sequence. It was essential to ensure that each case received the exact number of pizzas before inserting the divider and continuing without interruption.
Another key technical challenge was managing product entry into the robotic cell. The pizzas had to be spaced properly to enable the robots to pick them up precisely.
The solution: A vision-guided robotized case packing line with no product re-circulation
We developed a high-performance, modular case packing solution equipped with multi-laser, 3D vision technology. This system precisely detects the position, shape, and dimensions of products as they arrive from the production line. It ensures careful picking and efficient placement of products into cardboard cases that advance parallel to the conveyor.
The line features 12 high-speed pick-and-place robots that operate in perfect synchronization to maximize efficiency and minimize cycle times. The entire stainless-steel structure has a hygienic industrial design that simplifies cleaning and ensures compliance with the strictest food industry standards. At the line’s entry, an alignment and separation system adjusts the preorganized stream of the pizzas for optimal detection by the vision system.
Product handling is performed using mechanical systems to avoid contact with the toppings and to ensure gentle packing. The gripper heads are designed for quick changeovers, enabling fast adaptation to different pizza formats.
Thanks to its modular architecture and advanced programming, this line can adapt to different product formats and configurations. It provides a versatile, efficient packing solution that can grow with the customer’s needs.
What did we achieve?
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A fully automated process for maximum efficiency and consistency — fast and reliable to meet high production demands.
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Highly precise and hygienic operations, compliant with food safety standards.
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Minimal product handling to preserve product integrity and quality.
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Modular and scalable design, ready to adapt to future needs.
