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1. Shipper Magazine Assembly

1.1.3D Model

  • Product Contact Parts             -   SS304

  • Product Non-Contact Parts     -   MS, RAL 7035

Shipper Magazine

1.2 Shipper Magazine Assembly Operation

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  •  All shippers are stacked vertically into the magazine, and are accessed through a front opening called the picture frame.

  • The assembly consists of a sensor that detects whether there are enough shippers stacked. If the stack is low, an alarm is generated to alert the operator.

  • The magazine is motor-driven, which ensures that the shippers are always pushed forward from behind. This maintains consistent pressure, allowing each shipper to move toward the picture frame for every pluck operation.

2. Shipper Plucker Assembly

2.1.3D Model

  • Product Contact Parts             -   SS304

  • Product Non-Contact Parts     -   MS, RAL 7035

Shipper Plucker Assembly

2.2 Shipper Plucker Assembly Operation

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  • The Shipper Plucker Assembly is a vacuum-based Plucker assisted by a servo mechanism.

  • The Plucker grips the front surface of the shipper at the picture frame and then plucks it out using the servo.

  • After plucking, the shipper is formed and positioned over the flap folding assembly, where the flap folding operation is performed on the inserted shipper.

3. Flap Floding Assembly

3.1.3D Model

  • Product Contact Parts             -   SS304, 

  • Product Non-Contact Parts     -   MS, RAL 7035

Flap Folding Assembly

3.2 Flap Folding Assembly Operation

  • The Flap Folding Assembly is used for folding and tucking the the bottom flaps of the shipper do the subsequent sealing with tape.

  • It consists of four cylinders that close the two minor flaps and two major flap of the shipper, which operate after the shipper has been -plucked and formed properly.

4. Bottom Taping Assembly

4.1.3D Model

  • Product Contact Parts             -   SS304, 

  • Product Non-Contact Parts     -   MS, RAL 7035

Bottom Taping Assembly

4.2 Bottom Taping Assembly Operation

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  • The Bottom Taping Machine is used for sealing the bottom of the shipper after the flaps have been folded in the flap folding assembly.

  • The shipper is fed into the taping machine by a pusher from the flap folding assembly. It is then guided and moved by two side conveyors, which are motor-driven to ensure smooth and consistent transport through the taping head.

  • The taping head mechanism applies the tape to the bottom of the shipper, sealing it completely.

  • The PE sensor is present at the tape roll, where the presence of the tape roll is detected. If empty, it gives feedback to generate the alarm.

  • After sealing, the shipper is transferred to the Main Drive via,ready for further handling or packing.

5. Hopper and Main drive Assembly

5.1.3D Model

  • Product Contact Parts             -   SS304, 

  • Product Non-Contact Parts     -   MS, RAL 7035

Hopper Assembly

5.2 Hopper and Main Drive Assembly Operation

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  • The Hopper and Main drive Assembly is used to receive shippers from the Bottom Taping Machine and position them correctly for the next operation.

  • It consists of a hopper that temporarily holds the shipper, and a cylinder that descends the hopper into the top open cylinder for precise placement.

  • Two additional cylinders act as stoppers — one at the hopper and one before it — functioning as to control the shipper’s position accurately.

  • Then ensuring the shipper is ready for the robot operation.

  • After the robot places the matrix, the shipper is transferred smoothly to the Top Taping Assembly for the final sealing operation.

6.Infeed Conveyor  (For Bundle Bottles )

6.1. 3D Model

  • Product Contact Parts             -   SS304

  • Product Non-Contact Parts     -   MS, RAL 7035

Infeed Conveyor

6.2. Infeed Conveyor operation
 

  • The infeed conveyor assembly receives the product from the Bottle Infeed Conveyor / Source Machine and transfers it towards the Collation Platform Assembly for further processing.

  • The conveyor consists of a motor-driven belt system with sensors to detect product presence and ensure proper spacing and flow.

  • Based on the product detection, the conveyor moves the products forward at a controlled speed.

  • The assembly operates continuously and ensures smooth and consistent feeding of products to the collation unit for matrix formation.

7.Infeed Conveyor  (For loose Bottles)

7.1. 3D Model

  • Product Contact Parts             -   SS304

  • Product Non-Contact Parts     -   MS, RAL 7035

Infeed Conveyor

7.2. Infeed Conveyor operation
 

  • The infeed conveyor assembly receives the Loose bottles from the Loose Bottle Source / Previous Assembly and transfers them towards the Collation Platform Assembly for further processing.

  • The conveyor consists of a motor-driven belt system with sensors to detect Loose presence and ensure proper flow.

  • Based on the bundle detection, the conveyor moves the Loose Bottle forward at a controlled speed.

  • The assembly operates continuously and ensures smooth and consistent feeding of Loose bottles to the collation unit for matrix formation.

8. Collation Platform Assembly

8.1.3D Model

  • Product Contact Parts             -   SS304, 

  • Product Non-Contact Parts     -   MS, RAL 7035

collation platform Assembly

8.2 Collation Platform Assembly Operation

  • The collation platform assembly is used to form the product matrix for the robot to pick and place into the shipper using a servo-based positioning system for accurate control.

  • The working involves receiving products from the Infeed Conveyor Assembly and arranging them into two matrix formations based on the selected configuration, including loose bundle (36 bottles) and other bundle configurations as per product data.

  • The system ensures that at least one matrix is completely formed and properly aligned before sending a signal to the robot for pick-and-place operation, while the second matrix continues forming to maintain continuous flow.

9.Scara Robot for Matrix Pick & Place

9.1. 3D Model

9.2. Robot operation

  • The matrix transfer robot (i4-750H) receives the product matrix from the Collation Platform Assembly once the matrix formation is completed and a ready signal is generated.

  • Based on this signal, the robot performs pick operation by lifting the complete matrix using its gripper mechanism with precise positioning and synchronization.

  • The robot then transfers and places the picked matrix into the hopper of the Main Drive Assembly, ensuring correct placement and alignment for further processing.

  • The robot operates in continuous cycle, coordinating with the collation unit to maintain smooth flow of products and ensuring efficient transfer without interruption.

10.Layer Board Magazine

10.1. 3D Model

Layer Board Magazine

10.2. Layer Board Magazine operation

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  •  Layer Board Magazine Assembly and allows it to move towards the robot pick position using gravity.

  • The conveyor consists of free rollers mounted on a sloped structure, and the PLC control panel is mounted under the conveyor.

  • The layer board moves automatically due to gravity and reaches the defined pick location for the robot.

  • The assembly ensures simple, smooth, and continuous supply of layer boards for proper placement inside the shipper.

11.Scara Robot for Layer Board Pick & Place

11.1. 3D Model

11.2.Scara Robot For Layer Board Pick & Place operation

  • The robot (i4-550L) picks the shipper from the magazine/picture frame and transfers it to Vacuum Station-1 for further operation.

  • The robot holds the shipper using vacuum cups, opens the shipper, and places it at Vacuum Station-2 for positioning.For 118 ml shrink-wrap bundles, the robot checks layer board low-level detect and picks the layer board from the magazine when required.

  • The robot places the layer board at the bottom or middle of the shipper based on product matrix placement to ensure proper stacking and support.

12.Rotary Roller Conveyor

12.1. 3D Model

Rotary Roller Conveyor

12.2. Rotary Roller Conveyor operation
 

  • The rotary roller conveyor receives the shipper after taping, where taping confirmation is received before further movement.

  • Once the taping is confirmed, a signal is generated and the shipper is pulled onto the rotary conveyor section.

  • The conveyor then rotates the shipper by 90 degrees to change its orientation as required for downstream process.

  • After rotation, the shipper is transferred to the next roller conveyor for further operation.

13. Top Taping Assembly

13.1.3D Model

Top taping Assembly

  • Product Contact Parts             -   SS304, 

  • Product Non-Contact Parts     -   MS, RAL 7035

13.2 Top Taping Assembly Operation

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  • The assembly consists of cylinder mechanisms that fold and close the top major and minor flaps of the shipper before the tape is applied.

  • A photoelectric sensor at the start detects after the presence of the shipper to ensure the operation only begins when a shipper is correctly in position.

  • Another sensor is mounted near the tape roll to detect if the tape is running low or has run out, providing an alert to the operator and preventing incomplete sealing.

  • Once the flaps are folded and the tape is applied, the shipper is completely sealed and ready for further handling or packing.

14.Powered Roller Conveyor

14.1. 3D Model

Power Roller Conveyor

14.2. Rotary Roller Conveyor operation
 

  • The power roller conveyor receives the shipper from the Rotary Roller Conveyor Assembly and is continuously running to ensure smooth material flow.

  • Once the shipper is available, it is automatically conveyed forward without any start-stop delay due to continuous operation.

  • The conveyor transfers the shipper in a straight path while maintaining proper movement and spacing.

  • The shipper is then passed to the Checkweigher & Labelling Conveyor Assembly for weight verification.

15.Check Weigher 

15.1. 3D Model

Check Weigher 

15.2. Check Weigher  Conveyor operation
 

  • The checkweigher receives the shipper from the Power Roller Conveyor Assembly for weight verification.

  • The shipper is conveyed over the weighing section where its weight is measured using load cell.

  • The measured weight is compared with the set value to determine whether it is OK or Not OK.

  • If the weight is OK, a signal is passed to the Labelling Conveyor Assembly to proceed further; if not OK, the shipper is rejected.

16.Pre Label Applicator

16.1. 3D Model

Pre Label Applicator

16.2.Pre Label Applicator operation
 

  • After applying tape to the shipper, it will be transferred to the labelling conveyor.

  • The label applicator applies the label to the rear corner of the shipper.

17.Labelling Conveyor Assembly, OCR & OVC Camera

17.1. 3D Model

  • Product Contact Parts             -   SS304

  • Product Non-Contact Parts     -   MS, RAL 7035

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OCR&OVC Camera

17.2. Labelling conveyor operation

  • The flat belt labelling conveyor receives the taped shipper from the checkweigher and transfers it forward for further processing.

  • When the weight from the checkweigher is OK, a signal is received and the shipper is allowed to proceed for labeling operation.

  • The pre label applicator applies a pre-printed label on the shipper, and the shipper then passes through the OCR&OVC Camera for label verification.

  • If the label is OK, the shipper is sent to the accepted pallet through the conveyor; if not OK, it is rejected to the rejection pallet using a pneumatic mechanism.

18.Gravity Roller Shipper Rejection Conveyor

18.1. 3D Model

Gravity Roller Shipper Rejection Conveyor

Screenshot 2026-03-31 110857.png

18.2.Gravity Roller Shipper Rejction Conveyor operation
 

  • After applying tape to the shipper, it will be transferred to the labelling conveyor.

  • The label applicator applies the label to the rear corner of the shipper.

19.Palletizer Cobot

19.1. 3D Model

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  • The palletizer cobot (TM25S-X Cobot) picks the shipper from the palletizer Lable conveyor based on accepted and rejected signals.

  • The cobot palletizes the shipper according to the predefined pattern for accepted and rejected flow.

  • The cobot has a pneumatically operated pick head for handling the shipper during pick-and-place operation.

  • The pallet is placed manually  and the cobot performs automatic palletizing operation. 

19.2. Palletizer Cobot operation

20.Pallet Locator

20.1. 3D Model

Pallet Locator

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  • Main Structure     -  MS, RAL 7035

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  • Pallet Locator helps to load pallets at the correct location. Pallet locator has photoelectric sensors to detect pallet presence or absence.

20.2. Pallet Locator operation

21. Guards Assembly

21.1. 3D Model

Screenshot 2026-03-30 184643.png

21.2 Guard Assembly Operation

  • The guard assembly ensures the safety of personnel during the operation of the machine

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