Automated Case Packing for Higher Throughput at McAlpine
Explore how McAlpine & Co. Ltd implemented a fully automated case packing system to streamline packaging, increase throughput, and reduce manual labor.
Story Highlights
End-to-End Automation: From design to sourcing and Factory Acceptance Tests, McAlpine deployed a fully automated solution for case packing with Vention.
Labor Reallocation to High-Value Tasks: Automating repetitive, low-value tasks allowed operators to focus on more critical production work.
Exceeded Pick Speed Target: Vention’s platform and complementary design services helped McAlpine create a fully automated robotic cell to exceed their targets of 7.2 picks per minute.
Seamless Integration with Existing Operations: The automation system integrated smoothly with McAlpine’s extrusion and packaging processes, ensuring uninterrupted production gains.
The Problem
McAlpine & Co. Ltd’s production line was already highly automated, but case packing remained a manual process, requiring an operator to place products into boxes by hand. Given the 24/5 operation, this led to bottlenecks, labor costs, and repetitive work.
McAlpine sought an automated solution to remove manual labor from their packaging process. The key challenge was to increase production speed while maintaining quality.
Additionally, McAlpine wanted to free their operators from repetitive tasks, reallocating them to higher-value work within the facility.
"The design process using the Vention platform was like nothing we've used before. The majority of the time, automation suppliers will give you a 2D drawing. With Vention, it's all 3D. The ability to collaborate within the team and with Vention in real time was a game changer. The support we received from Vention after the factory acceptance test was exceptional. You can contact Vention immediately within 10 minutes of any issues."
The Project
The Vention team collaborated with McAlpine to capture their requirements and create a system design. The Vention MachineBuilder platform helped McAlpine to easily visualize the design and provide feedback.
Vention’s platform also made the complex procurement process very transparent, and the thorough deployment service ensured a smooth transition. Vention’s MachineMotion controller simplified system integration for McAlpine, making their factory floor future-proof.
The automated case packing system includes a UR10e cobot that picks and places products into cartons, optimizing the process based on the selected SKU. The system can package six different products into four different box sizes, with each SKU’s program tailored for its specific requirements. After packing, the cartons are transferred to a conveyor, sealed, and labeled—all without any human intervention.
The Results
By integrating a cobot-driven packaging system, McAlpine eliminated manual labor at the final stage of production, while significantly improving throughput and process reliability.
Post deployment, the McAlpine team was not only able to achieve their throughput targets but also exceeded them. Automating the packing process also ensured high quality, reducing while streamlining the 24/5 production cycle.
Beyond immediate operational benefits, this project has set a new standard for automation at McAlpine. With case packing now fully automated, the company is expanding its automation efforts to packaging and assembly cells, with a focus on integrating AI-powered bin picking.
This next step will further enhance production capabilities, optimize material handling, and position McAlpine for long-term growth.
Project Specs
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