Bag Palletizing Robot for Fertilizer Manufacturing

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Customer Requirement

MESH Automation provided a gantry palletizing solution for a manufacturing customer, using a vacuum-based end-of-arm tool to automate the pick-up and palletizing of large products, optimizing stack patterns with customized software.

The system achieved 95% overall equipment efficiency, offering flexibility and stability across six palletizing positions and six WIP tables.

A commercial fertilizer manufacturer required a palletizing solution for custom-blended 50-pound fertilizer bags, which came in a wide range of sizes. These blends are produced in large batches, filled through the bag’s open top, sewn shut, and then palletized. Manual palletizing was physically demanding and often led to ergonomic issues for plant personnel.

Mesh Solution

MESH designed a complete automation solution, which included the following key features:

  • Bag Upender and Turner System: This system fed a MESH square roller bag conditioner to flatten the bags and settle internal contents, creating a neater pallet easier to handle and ship.
  • ABB IRB460 Robot: The robot, equipped with an SAS claw tool, picks up each bag and places it onto the pallet. Additionally, a slip sheet vacuum tool lays a protective slip sheet on each new pallet.
  • Pallet Wrapping: The finished pallet is powered into a Phoenix wrapper equipped with a top hooder feature. Once wrapped, a top sheet is placed to protect the pallet during outdoor storage.

System Components

  • One ABB IRB460 palletizing robot with claw and slip sheet tool
  • Rockwell PLC and HMI package with conveyor drives and controls
  • MESH bag upender, turner, and conditioner systems
  • Bag and pallet conveyors for smooth bag movement and pallet transfer
  • MESH pallet dispenser and slip sheet magazine
  • Safety fencing and light curtains with access gates