BEYOND THE ROBOT
Keeping Production Supplied with Robotic Tote Depalletizing
Automated tote handling engineered to address a critical production bottleneck
The Next Fill Starts with an Empty Tote
The parts were ready. The filling equipment was ready. But when empty totes weren’t available, the line stopped.
For this manufacturer, large numbers of plastic totes remained in use for extended periods as filled totes moved through production and storage. Replenishing the supply of empty totes was critical to keeping the filling operation running.
Shortages created a bottleneck that significantly impacted throughput. Kaufman’s engineering team was given a specific need: automate empty-tote handling to keep production supplied.
Robotic tote depalletizing supports the continuous supply of empty totes needed at the production line filling station. Once each stack is placed on the conveyor, the tote de-stacker singulates them and they are conveyed back into the production line.
When Tote Availability Limits Throughput
A reusable tote may spend substantial time holding product before it becomes available again. Production keeps consuming empty totes while others remain occupied elsewhere in the process.
That makes the replenishment cycle essential. If empty totes cannot be put back into service when they are needed, the filling stations run out—and production stops.
The broader process explains why totes remain in use—and why an empty-tote shortage can interrupt the filling process. Illustration depicting the production dependency.
The customer needed a dependable way to put available empty totes back into production.
CLOSING THE LOOP FOR CONTINUOUS PRODUCTION
Automated empty-tote handling connects available supply to the next filling cycle
Robotic Tote Depalletizing System: Engineered Around the Need
Kaufman’s system takes palletized stacks of empty totes and prepares them for individual delivery to the parts-filling area. The robot, vision, tooling, and conveyor handling work together to complete that sequence.
1. LOCATE & DEPALLETIZE
Handle palletized tote stacks
FANUC 3DV vision locates stacked totes. A FANUC R-2000iC/165F robot uses a custom end-of-arm tool to remove stacks from the pallet and place them on a conveyor.
2. SEPARATE
Prepare Totes for Individual Handling
The tote separation equipment singulates the stacks, making individual empty totes available for the next step in the process.
3. SUPPLY FILLING SYSTEM
Put Empty Totes Back Into Production
The conveyor carries the separated totes to the candy-filling area, supporting the replenishment needed to keep the operation supplied and running smoothly.
Closing the loop on reusable totes
After their contents are used downstream, empty totes are stacked, palletized, and moved by forklift to a staging area. Those totes can later re-enter the depalletizing system for another filling cycle.
This staged supply connects tote reuse to production demand. The depalletizing system automates the handling required to put available empty totes back into service.
Engineering beyond the individual pick
The task was larger than removing totes from a pallet. The system needed to convert stacks into individual totes and deliver them in a form the filling operation could use.
Understanding that production dependency guided the integration of robotic picking, tote separation, and conveying around the customer’s replenishment need.
The Visual Story
This application was featured by FANUC America.
Key Takeaway
Throughput depends on keeping production supplied with the containers it needs. When empty totes run out, filling stops—even when the product and equipment are ready.
By automating the handling that puts empty totes back into use, Kaufman engineered a response to a critical replenishment bottleneck. That’s the thinking beyond the robot: understand the production need, then design the connected handling process to meet it.
Engineering Beyond Expectations
Effective automation starts with understanding what production needs to keep moving. Sometimes that means looking closely at a supporting process whose delays affect the entire line.
Kaufman brings robotics, tooling, controls, and material handling together around those requirements—engineering the system for the work it needs to do.
That’s the Kaufman difference.
Understand the Need
Identify what is limiting the operation.
Engineer the Connection
Coordinate the handling steps production depends on.
Support the Process
Design around the customer’s operating requirements.
Let's Start with Your Process
Is a material-handling bottleneck limiting your throughput? Tell us what needs to move, where it needs to go, and what happens when it doesn’t arrive on time.
We’ll help you explore automation engineered around your production needs.
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