Chapter 45: High-Speed Pick and Place |
45.1 Chapter Summary |
High-speed pick and place is one of the most visible and economically important applications of industrial robotics in the food and pharmaceutical industries. In simple terms, it is the automated process of rapidly picking individual items from a moving or stationary flow and placing them into a package, tray, blister pack, bottle, or secondary container. The challenge is not merely speed. The real challenge is combining speed with accuracy, gentleness, hygiene, and reliability when products arrive in irregular orientations, overlap one another, vary in shape, or move continuously on a conveyor. |
Vision-guided delta robots have become the dominant solution for these tasks. A delta robot is a parallel kinematic machine with three lightweight arms connected to a common base and a small moving platform. Because the motors are mounted on the base and the arms are light, the robot can accelerate and decelerate extremely quickly with very little inertia. When a camera or vision system is added, the robot can locate randomly oriented products and pick them without mechanical feeders or manual orientation. In modern food and beverage packaging lines, these systems routinely achieve pick accuracy above 99 percent on fast-moving, disorganized product flows, reducing errors, waste, and downtime. |
This chapter explains how high-speed pick and place works, why vision guidance matters, what system components are involved, and how the technology is applied across multiple industries. The emphasis is on practical examples rather than mathematics or design formulas. The goal is to help engineers, managers, students, and technical readers understand what these systems can do, where they fit, and what to consider when deploying them. |
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45.2 What High-Speed Pick and Place Means |
High-speed pick and place refers to robotic systems that can pick and place hundreds of items per minute. In food and beverage packaging, typical rates range from 60 to 300 picks per minute per robot, and some high-end delta systems exceed 400 picks per minute for small, light items. In pharmaceutical packaging, speeds are often lower because of strict traceability and handling requirements, but they can still reach 100 to 200 picks per minute for blister packs, vials, or small cartons. |
The phrase 'pick and place' covers several distinct tasks: |
1. Picking randomly oriented products from a bulk flow and placing them into a single-file lane or tray. |
2. Picking products from a moving conveyor and placing them into a package with a fixed orientation. |
3. Picking products from a tray or blister pack and placing them into a carton or secondary package. |
4. Picking products from a wide belt and sorting them into multiple output lanes. |
5. Picking products from a vibrating or tilting feeder and placing them into a high-speed wrapping or sealing system. |
In each case, the robot must solve three problems almost simultaneously: find the product, grasp it without damage, and place it accurately at high speed. |
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45.3 Why Vision Guidance Is Essential |
Without vision, a robot can only pick products that are already in a known position and orientation. That usually requires mechanical feeders, bowls, or orienting devices that singulate and align products before the robot picks them. Mechanical feeders are reliable for some products, but they are bulky, noisy, product-specific, and difficult to change over. They also struggle with fragile, sticky, irregular, or highly variable products. |
Vision guidance changes the problem. A camera looks at a broad area of product flow, identifies each item, calculates its position and orientation, and sends that information to the robot controller. The robot then picks the item directly from the disorganized flow. This eliminates or reduces the need for mechanical singulation and orientation. It also allows the system to handle multiple products on the same line, adapt to product changes in software, and recover from jams more gracefully. |
In food and beverage packaging, vision-guided delta systems are particularly valuable because products often arrive in a random mass. Cookies, crackers, candies, fresh produce, small bakery items, and frozen foods rarely arrive in perfect single file. They overlap, rotate, and vary in shape. A vision-guided delta robot can pick them one by one and place them into a tray or package with the correct orientation. |
In pharmaceutical packaging, vision guidance is equally important for a different reason. Products such as tablets, capsules, vials, syringes, and small medical devices must be handled with strict attention to orientation, count, and traceability. Vision systems can verify that the correct product is picked, that it is not damaged, and that it is placed in the correct cavity. |
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45.4 The Delta Robot Advantage |
The delta robot is a parallel robot with three arms that converge on a small platform. The platform carries a gripper, such as a vacuum cup, a soft gripper, or a mechanical jaw. The motors are fixed to the base, so the moving mass is low. This design allows very high acceleration and deceleration, often exceeding 10 g, and very short cycle times. |
Key advantages of delta robots for high-speed pick and place include: |
1. High speed. Delta robots can complete a pick-and-place cycle in as little as 0.2 to 0.5 seconds for small items. |
2. High repeatability. They can return to the same point with sub-millimeter precision, which is important for packaging. |
3. Large work envelope relative to size. A delta robot can reach a wide area above a conveyor without occupying much floor space. |
4. Flexible mounting. Delta robots are usually mounted above the product flow, leaving the conveyor area open for product movement and cleaning. |
5. Easy integration with vision. The robot controller can accept position data from a camera and adjust the pick point in real time. |
6. Gentle handling. With the right gripper, delta robots can handle fragile items such as cookies, pastries, and fresh fruit. |
Delta robots are not perfect for every task. They have a limited payload, typically from a few hundred grams to a few kilograms. They are not ideal for heavy or very large products. They also require a rigid frame and careful calibration. However, for small to medium-sized products in food and pharmaceutical packaging, they are often the best choice. |
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45.5 How a Vision-Guided Delta System Works |
A typical vision-guided delta pick-and-place system includes the following components: |
1. A delta robot with a controller. |
2. One or more cameras mounted above the product flow. |
3. A lighting system to make products visible and consistent. |
4. A conveyor or feeder that brings products into the robot's work area. |
5. A gripper matched to the product. |
6. An outfeed conveyor, tray, or packaging machine. |
7. A software layer that connects vision, robot, and packaging line. |
The process usually follows these steps: |
1. Products arrive on a conveyor in a random flow. |
2. A camera captures an image of the product flow. |
3. Vision software identifies each product and calculates its position, orientation, and sometimes its quality. |
4. The robot controller receives the list of products and plans a pick sequence. |
5. The robot moves to the first product, picks it, and places it in the target location. |
6. The vision system updates continuously, so the robot can track moving products and adjust to new arrivals. |
7. The packaging machine or outfeed system indexes to the next position. |
8. The cycle repeats at high speed. |
In advanced systems, the vision system can also track products on a moving conveyor. This is called visual tracking or conveyor tracking. The robot does not need to stop the conveyor. It picks the product while it is moving, matching its motion to the conveyor speed. This is essential for high-throughput lines. |
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45.6 Gripping Technologies for High-Speed Pick and Place |
The gripper is often the limiting factor in high-speed pick and place. A robot may be able to move quickly, but if the gripper cannot pick and release the product reliably, the system will fail. Common gripper types include: |
1. Vacuum cups. These are the most common for food and pharmaceutical products. They work well for flat, smooth, or semi-porous items such as cookies, crackers, tablets, and small cartons. Vacuum cups are fast, gentle, and easy to clean. |
2. Soft grippers. These are made from flexible materials such as silicone or rubber. They can conform to irregular shapes and handle fragile items such as fruit, vegetables, and baked goods. |
3. Mechanical jaws. These are used for products that cannot be picked with vacuum, such as porous or wet items. They can be designed with soft pads to avoid damage. |
4. Magnetic grippers. These are used in pharmaceutical or industrial packaging for metal components, but they are less common in food because of hygiene concerns. |
5. Electrostatic grippers. These are emerging for delicate items, but they are not yet common in high-speed food and pharmaceutical lines. |
6. Needle grippers. These are used for some meat and poultry products, but they raise hygiene concerns and are not suitable for many pharmaceutical products. |
In food and beverage packaging, vacuum cups and soft grippers dominate. They are fast, clean, and compatible with washdown environments. In pharmaceutical packaging, vacuum cups are common for tablets and capsules, while soft grippers are used for vials and syringes. |
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45.7 Vision Systems for High-Speed Pick and Place |
Vision systems for high-speed pick and place must be fast, accurate, and robust. They typically include: |
1. A camera. Area-scan cameras are common for random product flows. Line-scan cameras are used for continuous webs or very high-speed lines. |
2. A lens. The lens determines the field of view and resolution. A wider field of view allows more products to be seen, but it reduces resolution per product. |
3. Lighting. Proper lighting is critical. Backlighting, ring lighting, dome lighting, and dark-field lighting are common. The goal is to create consistent contrast between the product and the background. |
4. Image processing software. This software identifies products, calculates position and orientation, and rejects defects or foreign objects. |
5. Communication. The vision system must send data to the robot controller with very low latency. Ethernet, GigE Vision, and USB3 Vision are common. |
In food applications, vision systems must often handle variations in color, texture, and shape. A cookie may be broken. A strawberry may have a green stem. A piece of cheese may have irregular edges. The vision system must be trained or configured to recognize the product under these variations. In pharmaceutical applications, vision systems must be highly repeatable and traceable. They may need to verify count, orientation, and presence, and they may need to record images for audit trails. |
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45.8 Key Performance Metrics |
When evaluating a high-speed pick-and-place system, several metrics matter: |
1. Picks per minute. This is the number of products the robot can pick and place in one minute. It depends on robot speed, product size, gripper performance, and vision latency. |
2. Pick accuracy. This is the percentage of attempted picks that are successful. In modern food and beverage packaging, vision-guided delta systems can achieve over 99 percent accuracy on fast-moving, disorganized product flows. |
3. Placement accuracy. This is the ability to place the product in the correct position and orientation. It is often measured in millimeters or as a percentage of successful placements. |
4. Product damage rate. This is the percentage of products damaged during picking or placing. It is critical for fragile items such as cookies, pastries, and fresh produce. |
5. Uptime. This is the percentage of time the system is available for production. High-speed systems must be reliable and easy to maintain. |
6. Changeover time. This is the time required to switch from one product to another. Vision-guided systems can reduce changeover time because they can be reprogrammed in software rather than mechanically adjusted. |
7. Hygiene compliance. In food and pharmaceutical applications, the system must be cleanable and compatible with washdown, sanitizing chemicals, and contamination control. |
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45.9 Applications in Food and Beverage Packaging |
45.9.1 Bakery Products |
Bakeries produce cookies, crackers, biscuits, pastries, and bread rolls at high speed. These products often arrive in a random flow after baking and cooling. A vision-guided delta robot can pick individual cookies or crackers from a wide belt and place them into a tray or package. The vision system identifies each product, even if it is rotated or overlapping. The robot picks the product with a vacuum cup and places it in the correct orientation. This reduces labor, improves consistency, and increases throughput. |
In one typical application, a bakery produces 1,200 cookies per minute. Two delta robots, each with a vision system, pick the cookies from a conveyor and place them into a four-lane tray. The system achieves over 99 percent pick accuracy and reduces product damage compared to mechanical feeders. |
45.9.2 Confectionery |
Confectionery products include candies, chocolates, gummies, and chewing gum. These products are often small, sticky, and irregular. Vision-guided delta robots can pick them from a bulk flow and place them into bags, boxes, or blister packs. Soft grippers or vacuum cups with gentle contact are used to avoid damage. The vision system can also reject defective pieces, such as broken or misshapen candies. |
In chocolate packaging, delta robots are used to pick individual chocolates from a conveyor and place them into a gift box. The vision system ensures that each chocolate is placed in the correct orientation and that the box is complete. This application requires high accuracy and gentle handling because chocolate can melt or crack. |
45.9.3 Fresh Produce |
Fresh produce includes fruits and vegetables such as apples, oranges, strawberries, tomatoes, and peppers. These products are fragile and vary in size, shape, and color. Vision-guided delta robots can pick them from a conveyor and place them into trays or punnets. Soft grippers are often used to avoid bruising. The vision system can sort by size, color, and quality, so the robot can place premium products in one package and lower-grade products in another. |
In strawberry packaging, a vision-guided delta system can pick individual strawberries from a conveyor and place them into a punnet with the stem facing up. The vision system identifies the stem and the orientation of each strawberry. The robot uses a soft gripper to pick the strawberry without damaging it. This application improves presentation and reduces waste. |
45.9.4 Snack Foods |
Snack foods include potato chips, tortilla chips, pretzels, and nuts. These products are lightweight, fragile, and often irregular in shape. Vision-guided delta robots can pick them from a conveyor and place them into bags or containers. Vacuum cups are often used, but the vacuum must be controlled carefully to avoid crushing the product. The vision system can also detect broken or burned pieces and reject them. |
In potato chip packaging, a delta robot picks individual chips from a conveyor and places them into a canister. The vision system identifies each chip and ensures that it is placed flat. This application requires high speed and gentle handling because chips are fragile and lightweight. |
45.9.5 Meat, Poultry, and Seafood |
Meat, poultry, and seafood products are often irregular, wet, and sticky. Vision-guided delta robots can pick them from a conveyor and place them into trays or packages. Soft grippers or special vacuum cups are used to handle the products without damage. The vision system can sort by size, shape, and quality. In some cases, the robot can also apply a marinade or seasoning before placing the product. |
In chicken nugget packaging, a vision-guided delta system picks individual nuggets from a conveyor and places them into a tray. The vision system identifies each nugget and ensures that it is placed in the correct orientation. The robot uses a soft gripper to avoid damaging the coating. |
45.9.6 Dairy Products |
Dairy products include cheese, butter, yogurt cups, and ice cream. These products can be delicate and temperature-sensitive. Vision-guided delta robots can pick them from a conveyor and place them into packages or trays. Vacuum cups are common for cheese slices and butter portions. Soft grippers are used for yogurt cups and ice cream containers. |
In cheese packaging, a delta robot picks individual cheese slices from a conveyor and places them into a stack. The vision system ensures that each slice is flat and that the stack is complete. This application requires high speed and accurate placement. |
45.9.7 Frozen Foods |
Frozen foods include frozen vegetables, fruits, dumplings, and prepared meals. These products are often hard and irregular. Vision-guided delta robots can pick them from a conveyor and place them into bags or boxes. Vacuum cups or mechanical grippers are used, depending on the product. The vision system can sort by size and shape. |
In frozen dumpling packaging, a vision-guided delta system picks individual dumplings from a conveyor and places them into a tray. The vision system identifies each dumpling and ensures that it is placed in the correct orientation. The robot uses a vacuum cup to pick the dumpling without damaging it. |
45.9.8 Beverage Packaging |
Beverage packaging includes bottles, cans, caps, and labels. High-speed pick and place is used for tasks such as placing caps on bottles, picking bottles from a conveyor and placing them into a carton, and sorting empty bottles. Vision-guided delta robots can handle these tasks at high speed. Vacuum cups are used for caps and small bottles. Mechanical grippers are used for larger bottles. |
In bottle cap packaging, a delta robot picks caps from a conveyor and places them onto bottles. The vision system ensures that each cap is correctly oriented and that the bottle is in the correct position. This application requires high speed and high accuracy. |
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45.10 Applications in Pharmaceutical Packaging |
45.10.1 Tablets and Capsules |
Tablets and capsules are small, uniform, and often produced in high volumes. Vision-guided delta robots can pick them from a conveyor or blister pack and place them into bottles, blister packs, or cartons. Vacuum cups are commonly used. The vision system can verify count, orientation, and presence. It can also reject broken or discolored tablets. |
In tablet packaging, a delta robot picks individual tablets from a conveyor and places them into a blister pack. The vision system ensures that each cavity is filled and that the tablet is in the correct orientation. This application requires high accuracy and strict traceability. |
45.10.2 Vials and Syringes |
Vials and syringes are used for injectable medications. They are often small, fragile, and must be handled with strict attention to hygiene and traceability. Vision-guided delta robots can pick them from a conveyor and place them into trays or nests. Soft grippers or special vacuum cups are used to avoid damage. The vision system can verify the presence, orientation, and integrity of each vial or syringe. |
In vial packaging, a delta robot picks individual vials from a conveyor and places them into a tray. The vision system ensures that each vial is upright and that the tray is complete. This application requires high accuracy and gentle handling. |
45.10.3 Medical Devices |
Medical devices include catheters, syringes, lancets, and test strips. These products are often small, delicate, and must be handled in a clean environment. Vision-guided delta robots can pick them from a conveyor and place them into packages or trays. Soft grippers or vacuum cups are used. The vision system can verify the presence and orientation of each device. |
In test strip packaging, a delta robot picks individual test strips from a conveyor and places them into a vial. The vision system ensures that each strip is correctly oriented and that the vial is filled. This application requires high speed and high accuracy. |
45.10.4 Blister Packs |
Blister packs are used for tablets, capsules, and small medical devices. Vision-guided delta robots can pick products from a conveyor and place them into blister cavities. The vision system ensures that each cavity is filled and that the product is in the correct orientation. This application requires high accuracy and strict quality control. |
In blister pack packaging, a delta robot picks individual tablets from a conveyor and places them into a blister pack. The vision system verifies that each cavity is filled and that the tablet is not damaged. The blister pack is then sealed and cut into individual doses. |
45.10.5 Sterile Packaging |
Sterile packaging is used for surgical instruments, implants, and other medical devices. These products must be handled in a cleanroom environment. Vision-guided delta robots can be designed for cleanroom use with stainless steel construction, sealed motors, and washdown capability. The vision system can verify the presence and orientation of each product. Soft grippers or vacuum cups are used to avoid damage. |
In sterile packaging, a delta robot picks individual surgical instruments from a conveyor and places them into a sterile tray. The vision system ensures that each instrument is correctly oriented and that the tray is complete. This application requires strict hygiene and traceability. |
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45.11 Applications in Other Industries |
45.11.1 Electronics |
High-speed pick and place is widely used in electronics manufacturing for placing components on printed circuit boards. Vision-guided delta robots can pick small components from a feeder and place them on a board with high accuracy. Vacuum cups are commonly used. The vision system ensures that each component is correctly oriented and placed. |
In smartphone assembly, a delta robot picks small components such as camera modules and speakers from a tray and places them into the phone housing. The vision system ensures that each component is correctly oriented and that the placement is accurate. This application requires high speed and high precision. |
45.11.2 Cosmetics |
Cosmetics packaging includes lipsticks, compacts, and creams. Vision-guided delta robots can pick products from a conveyor and place them into packages or trays. Vacuum cups or soft grippers are used. The vision system can verify the presence and orientation of each product. |
In lipstick packaging, a delta robot picks individual lipstick tubes from a conveyor and places them into a display tray. The vision system ensures that each tube is correctly oriented and that the tray is complete. This application requires high speed and gentle handling. |
45.11.3 Consumer Goods |
Consumer goods include pens, razors, toothbrushes, and small household items. Vision-guided delta robots can pick them from a conveyor and place them into packages or trays. Vacuum cups or mechanical grippers are used. The vision system can verify the presence and orientation of each product. |
In razor packaging, a delta robot picks individual razors from a conveyor and places them into a blister pack. The vision system ensures that each razor is correctly oriented and that the blister pack is complete. This application requires high speed and accurate placement. |
45.11.4 Automotive Components |
Automotive components include small parts such as screws, clips, and connectors. Vision-guided delta robots can pick them from a conveyor and place them into trays or assembly fixtures. Vacuum cups or mechanical grippers are used. The vision system can verify the presence and orientation of each part. |
In connector assembly, a delta robot picks individual connectors from a conveyor and places them into a housing. The vision system ensures that each connector is correctly oriented and that the housing is complete. This application requires high speed and high accuracy. |
45.11.5 Agricultural Products |
Agricultural products include seeds, grains, and small plants. Vision-guided delta robots can pick them from a conveyor and place them into trays or pots. Soft grippers or vacuum cups are used. The vision system can sort by size, shape, and quality. |
In seedling transplanting, a delta robot picks individual seedlings from a tray and places them into a larger pot. The vision system ensures that each seedling is correctly oriented and that the pot is filled. This application requires gentle handling and high accuracy. |
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45.12 System Integration Considerations |
Integrating a high-speed pick-and-place system into a production line requires careful planning. Key considerations include: |
1. Product flow. The system must be designed to handle the actual product flow, including variations in size, shape, and orientation. The conveyor speed and width must be matched to the robot's work envelope. |
2. Vision system. The camera, lens, and lighting must be selected for the specific product and environment. The vision system must be fast enough to keep up with the robot and accurate enough to meet quality requirements. |
3. Robot selection. The robot must have enough reach, payload, and speed for the application. Delta robots are common, but other robot types may be better for some tasks. |
4. Gripper design. The gripper must be matched to the product. It must be fast, reliable, and gentle. It must also be easy to clean and maintain. |
5. Control system. The robot controller must communicate with the vision system and the packaging line. It must be able to handle high-speed data and real-time decisions. |
6. Hygiene. In food and pharmaceutical applications, the system must be designed for easy cleaning and sanitizing. Stainless steel, washdown motors, and food-grade materials are common. |
7. Safety. The system must comply with safety standards. Light curtains, safety fences, and emergency stops are common. |
8. Maintenance. The system must be easy to maintain. Quick-change grippers, modular components, and remote diagnostics can reduce downtime. |
9. Training. Operators and maintenance staff must be trained to use and service the system. A well-designed human-machine interface can make this easier. |
10. Validation. In pharmaceutical applications, the system may need to be validated for accuracy, repeatability, and traceability. Documentation and audit trails are important. |
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45.13 Benefits of High-Speed Pick and Place |
The benefits of high-speed pick and place in food and pharmaceutical packaging include: |
1. Increased throughput. Delta robots can pick and place hundreds of items per minute, far faster than human workers. |
2. Improved accuracy. Vision-guided systems can achieve over 99 percent pick accuracy, reducing errors and waste. |
3. Reduced labor. Automation reduces the need for manual picking and placing, which can be repetitive and tiring. |
4. Improved hygiene. Robots can operate in cleanrooms and washdown environments, reducing the risk of contamination. |
5. Greater flexibility. Vision-guided systems can handle multiple products and can be reprogrammed in software. |
6. Reduced product damage. With the right gripper and vision system, robots can handle fragile products gently. |
7. Better traceability. Vision systems can record images and data for audit trails, which is important in pharmaceutical packaging. |
8. Higher uptime. Modern systems are reliable and easy to maintain, reducing downtime. |
9. Consistent quality. Robots do not get tired or distracted, so they maintain consistent quality throughout the shift. |
10. Scalability. Additional robots can be added to increase capacity as needed. |
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45.14 Challenges and Limitations |
High-speed pick and place is not without challenges. Some of the most common include: |
1. Product variation. Products that vary widely in size, shape, or color can be difficult for vision systems to handle. Training and configuration are important. |
2. Gripper limitations. Some products are difficult to pick with vacuum cups or soft grippers. Mechanical grippers may be needed, but they can be slower or less gentle. |
3. Speed limitations. The robot may be fast, but the vision system, gripper, or packaging machine may be the bottleneck. |
4. Hygiene requirements. Food and pharmaceutical applications require strict hygiene. The system must be designed for easy cleaning and sanitizing. |
5. Cost. High-speed pick-and-place systems can be expensive. The return on investment depends on labor savings, throughput gains, and quality improvements. |
6. Integration complexity. Integrating vision, robot, and packaging line can be complex. It requires careful planning and experienced engineers. |
7. Maintenance. High-speed systems require regular maintenance. Grippers, vacuum cups, and cameras may need to be replaced periodically. |
8. Safety. High-speed robots can be dangerous. Safety systems must be designed and maintained properly. |
9. Validation. Pharmaceutical applications may require validation, which can be time-consuming and expensive. |
10. Changeover. Changing from one product to another can require new grippers, new vision settings, and new programming. Vision-guided systems reduce changeover time, but they do not eliminate it. |
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45.15 Recent Advances |
Recent advances in high-speed pick and place include: |
1. Faster vision systems. New cameras and processors can capture and analyze images in milliseconds, reducing latency and increasing pick rates. |
2. Better grippers. New soft grippers and vacuum cups are more gentle, more reliable, and easier to clean. |
3. Improved robot control. New control algorithms allow delta robots to move faster and more smoothly, reducing vibration and improving accuracy. |
4. Artificial intelligence. Machine learning is being used to improve vision systems, allowing them to recognize products under difficult conditions and to adapt to changes. |
5. Collaborative robots. Some high-speed pick-and-place systems use collaborative robots that can work safely alongside humans. |
6. Modular systems. Modular components make it easier to build and reconfigure high-speed pick-and-place systems. |
7. Digital twins. Digital twins are used to simulate and optimize high-speed pick-and-place systems before they are built. |
8. Cloud connectivity. Cloud connectivity allows remote monitoring, diagnostics, and updates. |
9. Energy efficiency. New systems are more energy-efficient, reducing operating costs. |
10. Hygiene improvements. New materials and designs make it easier to clean and sanitize high-speed pick-and-place systems. |
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45.16 Case Studies |
45.16.1 Case Study: Cookie Packaging |
A large bakery produces 1,500 cookies per minute. The cookies arrive in a random flow on a wide belt. The bakery installs two vision-guided delta robots, each with a vacuum gripper and a camera. The robots pick the cookies from the belt and place them into a four-lane tray. The vision system identifies each cookie and calculates its position and orientation. The robots achieve over 99 percent pick accuracy and reduce product damage by 30 percent compared to the previous mechanical system. The system also reduces labor by 50 percent and increases throughput by 20 percent. |
45.16.2 Case Study: Chocolate Packaging |
A chocolate manufacturer produces assorted chocolates in a variety of shapes. The chocolates arrive in a random flow on a conveyor. The manufacturer installs a vision-guided delta robot with a soft gripper and a camera. The robot picks the chocolates from the conveyor and places them into a gift box. The vision system identifies each chocolate and ensures that it is placed in the correct orientation. The system achieves over 99 percent pick accuracy and reduces product damage by 25 percent. The system also allows the manufacturer to change the assortment quickly by reprogramming the vision system. |
45.16.3 Case Study: Strawberry Packaging |
A fresh produce company packages strawberries into punnets. The strawberries arrive in a random flow on a conveyor. The company installs a vision-guided delta robot with a soft gripper and a camera. The robot picks the strawberries from the conveyor and places them into a punnet with the stem facing up. The vision system identifies the stem and the orientation of each strawberry. The system achieves over 99 percent pick accuracy and reduces product damage by 40 percent. The system also improves presentation and reduces waste. |
45.16.4 Case Study: Tablet Packaging |
A pharmaceutical company produces tablets in high volumes. The tablets arrive in a random flow on a conveyor. The company installs a vision-guided delta robot with a vacuum gripper and a camera. The robot picks the tablets from the conveyor and places them into a blister pack. The vision system verifies that each cavity is filled and that the tablet is not damaged. The system achieves over 99.9 percent pick accuracy and provides full traceability. The system also reduces labor by 60 percent and increases throughput by 30 percent. |
45.16.5 Case Study: Vial Packaging |
A pharmaceutical company produces vials for injectable medications. The vials arrive in a random flow on a conveyor. The company installs a vision-guided delta robot with a soft gripper and a camera. The robot picks the vials from the conveyor and places them into a tray. The vision system verifies that each vial is upright and that the tray is complete. The system achieves over 99.9 percent pick accuracy and provides full traceability. The system also reduces product damage by 50 percent. |
45.16.6 Case Study: Electronics Assembly |
An electronics manufacturer produces smartphones. Small components such as camera modules and speakers arrive in trays. The manufacturer installs a vision-guided delta robot with a vacuum gripper and a camera. The robot picks the components from the trays and places them into the phone housing. The vision system ensures that each component is correctly oriented and that the placement is accurate. The system achieves over 99.9 percent pick accuracy and increases throughput by 25 percent. |
45.16.7 Case Study: Razor Packaging |
A consumer goods company produces razors. The razors arrive in a random flow on a conveyor. The company installs a vision-guided delta robot with a vacuum gripper and a camera. The robot picks the razors from the conveyor and places them into a blister pack. The vision system ensures that each razor is correctly oriented and that the blister pack is complete. The system achieves over 99 percent pick accuracy and increases throughput by 20 percent. |
45.16.8 Case Study: Seedling Transplanting |
An agricultural company produces seedlings. The seedlings arrive in trays. The company installs a vision-guided delta robot with a soft gripper and a camera. The robot picks the seedlings from the trays and places them into larger pots. The vision system ensures that each seedling is correctly oriented and that the pot is filled. The system achieves over 99 percent pick accuracy and reduces labor by 70 percent. |
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45.17 Best Practices |
To get the most from a high-speed pick-and-place system, follow these best practices: |
1. Start with the product. Understand the product's size, shape, weight, fragility, and variability. This will drive the choice of robot, gripper, and vision system. |
2. Design for the product flow. Make sure the conveyor, feeder, and outfeed system are matched to the robot's speed and reach. |
3. Choose the right gripper. The gripper is often the key to success. Test multiple grippers if possible. |
4. Invest in good lighting. Lighting is critical for vision system performance. Do not cut corners on lighting. |
5. Plan for hygiene. In food and pharmaceutical applications, design for easy cleaning and sanitizing from the start. |
6. Plan for changeover. Use software-configurable vision systems and quick-change grippers to reduce changeover time. |
7. Monitor performance. Use data to track pick accuracy, placement accuracy, product damage, and uptime. |
8. Maintain the system. Follow the manufacturer's maintenance schedule. Replace worn grippers and vacuum cups regularly. |
9. Train operators. Make sure operators and maintenance staff understand the system and can troubleshoot common issues. |
10. Validate the system. In pharmaceutical applications, validate the system for accuracy, repeatability, and traceability. |
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45.18 Safety Considerations |
High-speed pick-and-place systems can be dangerous. Delta robots move quickly and can cause injury if someone enters the work envelope. Safety considerations include: |
1. Safety fences. Physical barriers should be used to keep people out of the robot's work area. |
2. Light curtains. Light curtains can detect when someone enters the work area and stop the robot. |
3. Emergency stops. Emergency stop buttons should be located around the system. |
4. Safety-rated controllers. The robot controller should be safety-rated and should include safety functions such as safe stop and safe speed. |
5. Risk assessment. A risk assessment should be performed before the system is installed. |
6. Training. Operators and maintenance staff should be trained on safety procedures. |
7. Lockout tagout. Maintenance should follow lockout tagout procedures. |
8. Hygiene and safety. In food and pharmaceutical applications, safety systems must be designed to be cleanable and compatible with washdown. |
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45.19 Economic Considerations |
The economic case for high-speed pick and place depends on several factors: |
1. Labor savings. Automation can reduce the need for manual picking and placing. This is often the largest source of savings. |
2. Throughput gains. Higher throughput can increase revenue and reduce unit costs. |
3. Quality improvements. Higher accuracy and less product damage can reduce waste and improve customer satisfaction. |
4. Flexibility. Vision-guided systems can handle multiple products, reducing the need for dedicated equipment. |
5. Uptime. Reliable systems reduce downtime and increase production. |
6. Maintenance. Regular maintenance is required, but modern systems are designed to be easy to maintain. |
7. Installation. Installation costs can be significant, especially for complex systems. |
8. Training. Training costs should be considered. |
9. Validation. In pharmaceutical applications, validation costs should be considered. |
10. Return on investment. The return on investment depends on the specific application. In many food and beverage applications, the payback period is one to three years. In pharmaceutical applications, it may be longer because of validation requirements. |
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45.20 Future Trends |
The future of high-speed pick and place is likely to include: |
1. Faster and more accurate vision systems. New cameras and processors will continue to improve speed and accuracy. |
2. Smarter robots. Artificial intelligence and machine learning will make robots more adaptable and easier to program. |
3. More flexible grippers. New materials and designs will make grippers more gentle, more reliable, and easier to clean. |
4. Collaborative systems. Collaborative robots will allow humans and robots to work together more safely and efficiently. |
5. Modular systems. Modular components will make it easier to build and reconfigure high-speed pick-and-place systems. |
6. Digital twins. Digital twins will be used to simulate and optimize systems before they are built. |
7. Cloud connectivity. Cloud connectivity will allow remote monitoring, diagnostics, and updates. |
8. Energy efficiency. New systems will be more energy-efficient, reducing operating costs. |
9. Hygiene improvements. New materials and designs will make it easier to clean and sanitize high-speed pick-and-place systems. |
10. Integration with packaging lines. High-speed pick-and-place systems will become more integrated with packaging lines, reducing the need for separate machines. |
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45.21 Detailed Summary |
High-speed pick and place is a critical technology in food and pharmaceutical packaging. Vision-guided delta systems improve pick accuracy to over 99 percent on fast-moving, disorganized product flows, reducing errors in food and beverage packaging. This chapter has explained how these systems work, why vision guidance is essential, what components are involved, and how the technology is applied across multiple industries. |
The key points are as follows: |
1. High-speed pick and place involves rapidly picking individual items from a moving or stationary flow and placing them into a package, tray, blister pack, bottle, or secondary container. |
2. Vision guidance is essential because it allows the robot to locate randomly oriented products and pick them without mechanical feeders or manual orientation. |
3. Delta robots are the dominant solution for high-speed pick and place because they are fast, accurate, and flexible. |
4. A typical system includes a delta robot, one or more cameras, a lighting system, a conveyor or feeder, a gripper, an outfeed system, and software. |
5. Gripping technologies include vacuum cups, soft grippers, mechanical jaws, magnetic grippers, electrostatic grippers, and needle grippers. |
6. Vision systems must be fast, accurate, and robust. They include a camera, a lens, lighting, image processing software, and communication. |
7. Key performance metrics include picks per minute, pick accuracy, placement accuracy, product damage rate, uptime, changeover time, and hygiene compliance. |
8. Applications in food and beverage packaging include bakery products, confectionery, fresh produce, snack foods, meat, poultry, seafood, dairy products, frozen foods, and beverage packaging. |
9. Applications in pharmaceutical packaging include tablets and capsules, vials and syringes, medical devices, blister packs, and sterile packaging. |
10. Applications in other industries include electronics, cosmetics, consumer goods, automotive components, and agricultural products. |
11. System integration considerations include product flow, vision system, robot selection, gripper design, control system, hygiene, safety, maintenance, training, and validation. |
12. Benefits include increased throughput, improved accuracy, reduced labor, improved hygiene, greater flexibility, reduced product damage, better traceability, higher uptime, consistent quality, and scalability. |
13. Challenges include product variation, gripper limitations, speed limitations, hygiene requirements, cost, integration complexity, maintenance, safety, validation, and changeover. |
14. Recent advances include faster vision systems, better grippers, improved robot control, artificial intelligence, collaborative robots, modular systems, digital twins, cloud connectivity, energy efficiency, and hygiene improvements. |
15. Case studies from cookie packaging, chocolate packaging, strawberry packaging, tablet packaging, vial packaging, electronics assembly, razor packaging, and seedling transplanting demonstrate the effectiveness of the technology. |
16. Best practices include starting with the product, designing for the product flow, choosing the right gripper, investing in good lighting, planning for hygiene, planning for changeover, monitoring performance, maintaining the system, training operators, and validating the system. |
17. Safety considerations include safety fences, light curtains, emergency stops, safety-rated controllers, risk assessment, training, lockout tagout, and hygiene and safety. |
18. Economic considerations include labor savings, throughput gains, quality improvements, flexibility, uptime, maintenance, installation, training, validation, and return on investment. |
19. Future trends include faster and more accurate vision systems, smarter robots, more flexible grippers, collaborative systems, modular systems, digital twins, cloud connectivity, energy efficiency, hygiene improvements, and integration with packaging lines. |
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In conclusion, high-speed pick and place is a mature and rapidly evolving technology. Vision-guided delta systems have transformed food and pharmaceutical packaging by enabling fast, accurate, and gentle handling of products in disorganized flows. As vision systems, grippers, and robot control continue to improve, these systems will become even more capable, flexible, and affordable. For engineers and managers in food and pharmaceutical packaging, understanding this technology is essential for staying competitive in a demanding market. |
cs@easiersoft.com