Foodie fads spark robot rethink
TV cooking programmes are driving legions of fans back into the kitchen. Seven of the top ten most-seen shows of 2015 were episodes of Bake Off, with demands for specific ingredients and products featured, sparking a sales bonanza after each broadcast. Similarly, a slew of new dinner kits, is inspiring home cooks to prepare more ambitious meals at a fraction of the effort. This trend is compelling retailers to rethink store layouts, how they group products together for consumer convenience and how swiftly they react to the scramble for the latest ‘must have’ ingredient or kitchen gadget.
As a result of these developments, there’s been a surge of interest among food suppliers for robotics, observes Paul Wilkinson, business development manager at automation specialist Pacepacker Services. “Shows like MasterChef, Bake Off and celebrity cookery programmes, combined with a desire to lead healthier lives using fresh ingredients, are influencing people to cook everything from exotic cuisines to local produce from scratch. Almost half the nation is now more inclined to shop for recipe ingredients when they need them. Food suppliers are exploring pick and place and packing solutions to ensure consumers have access to the freshest, most seasonal produce, and all the ingredients to whip up a menu showstopper.”
Like any trend, however, there remains a concern among manufacturers that today’s advanced system could become tomorrow’s expensive mistake as the food industry continues to evolve. Guiding wary automation first-timers, Pacepacker provides some helpful pointers to help minimise the future risk when adopting automation.
Consumers lead the way
Automation isn’t just about keeping up with the latest fad, but also anticipating what will emerge next. If we’ve learned one thing, it’s that consumer behaviour leads the way. Right now, it seems the population is hungry for help in the kitchen. Thankfully, automation systems today flex to these changing needs and can easily be reprogrammed to perform a different task.
“Five years ago, who’d have thought that our mega-supermarkets would be stripping back their extensive ranges to create a simpler, easier to navigate shopping experience,” comments Wilkinson. “The grocery sector is having to be even more psychologically innovative, and this includes overhauling the layouts of aisles and grouping products, such as all of the components for stir fries, pasta dishes, or cake making, together. Busy lifestyles means consumers today don’t want to graze around the store as much. If they have a list of recipe ingredients, they want everything to be located logically near to each other, so they can be in and out of the shop quickly. To cater to this trend and help ensure even the smaller stores have what people need, retailers are increasingly asking suppliers to prepare mixed trays and cases.”
Reacting to this evolution, Pacepacker created its Mixed Tray Loader – the first known invention of its kind to automate product swapping. It enables companies to pack an array of products into a tray or delivery box. When handling ingredients such as meat, fish and dairy, same day turnaround is vital to maintain freshness.
Companies like ‘HelloFresh’ – which has over 250,000 regular monthly subscribers – are also enjoying considerable success, delivering weekly boxes direct to customers filled with a variety of meat trays and stock pots, fresh fruit and veg and spice sachets, according to the recipes selected by subscribers. “For food producers supplying this booming market, product quality and freshness are the underpinning factors,” says Wilkinson. “Even for a small operation, products need to be shipped fast and automation is a key tool for picking, packing and delivering orders within tight timeframes.”
Trend today, gone tomorrow
Trends are trends. While some stick, others don’t. And then there are some classics that rarely go out of style. According to the Hot Food & Beverage Trends 2016/2017 report, fat is back, souping is the new juicing and subscription meal and cocktail kits are predicted to grow further in popularity this year.
Given the speed in which tastes and shopping habits change, agnostic equipment buyers need assurance that the automation solution specified can be adapted. “Most robotic systems can store as standard a range of different programs for different applications – 25 to 50 is typical – and these will cater for the foreseeable needs of most users,” highlights Wilkinson.
For seasonal food producers, this is especially reassuring. It means that you can switch between packing punnets of blueberries with cherries or strawberries, depending on what’s being harvested. “Realistically, someone packing soft fruits is unlikely to start packing turkeys or birdseed, yet flexibility is still paramount when selecting a system,” notes Wilkinson.
Major reprogramming is possible if additional applications arise beyond the scope of the existing programs. “It’s perfectly feasible for properly trained operatives to carry out reprogramming themselves, although for more complex applications it may be easier to call in the supplier, who deals with robotics programs on a day-to-day basis,” says Wilkinson.
No end to end-effector innovation
Whether you’ve commissioned a Cartesian system, Delta robot or robotic arm, the handling capability of a robotic system ultimately depends on its end effector. Although most food producers have a tendency to handle similar products, commissioning the most appropriate gripper for their application, if the business changes, swapping tooling is relatively straightforward.
Multitasking end effectors are also more commonplace today. Last year, Pacepacker developed an innovative shingle tray loader with an end effector that can handle any type of fresh and ambient form, fill and seal packs. “Like any readily available commodity, a pick and place robot ‘out of the box’ will accomplish very little,” claims Wilkinson. “It’s the ancillaries, applications knowledge, software and set-up you apply that make the difference.”
Taking in the bigger picture
Vision systems might seem like an obvious way to go in order to improve adaptability. However, they can be as complex as the robots themselves to set up. “Where possible it is usually preferable to try to orientate and singulate product units through the use of lanes and other handling techniques, rather than relying on cameras,” suggests Wilkinson.
Even so, there are times when vision systems can be extremely helpful. Perhaps it’s very difficult to pre-orientate the product or maybe products are arriving at a pick and place station at very high rates that require multiple robots to cooperate, for example chocolates and bakery items going into trays and selection boxes of cheeses. Similarly, irregular shaped products, such as nuts packed in pillow bags, fresh cheese, avocados or frozen berries, might need the support of vision systems to detect the variations in height to ensure the robot retrieves and handles them gently, reducing the risk of product damage.
Building in wriggle room
Given how fast moving today’s food business is, when choosing a system, a good rule of thumb is to specify a contingency of 10 to 20% in terms of payload or speed. In Pacepacker’s experience, it’s not that uncommon for requirements to change even before the automation project is complete.
Any system supplier should factor this in and be able to advise about optimising the balance between building in flexibility for possible future expansion and cost. “We always try to build in something extra in reserve,” adds Wilkinson.
Select the silver service menu
Although a takeaway fills an immediate hunger, when investing in automation, it’s reassuring to know you have the a la carte menu for support and to adapt to changing production needs. The provision of spares, training, technical support and preventive maintenance services can all be key factors in determining how successfully an automated system performs in the long run.
“With appropriate servicing and support, an automated packing or pick and place system should run reliably for many years, we have robotic systems installed in 2002/3 that are still in full production 13 years on with no reports of any issues.,” claims Wilkinson.
Whatever food trends are on the scene or about to emerge, the robot revolution looks set to stay. “The food industry is facing a paradigm shift, where product freshness and quality rely on speed to market,” concludes Wilkinson. “Today’s generation of automated pick and pack systems are flexible enough to adapt to changing consumers patterns and preferences, which in the food sector is the mandate for success.”
Other News from Pacepacker Services Ltd

Latest news about Robotics
- Next generation production line for Pets Choice
- Universal Robots launches vast online knowledge bank
- IP44 robolink from Igus defies water
- Hire a robot from just £63.99 per day
- Igus demonstrates Robolink in splash water applications
- Robot range is quickly extended with the new 7th axis from Igus
- Re-energising European battery cell production
- Omron appoints Reeco Automation as solution partner for collaborative robots
- Cobots key to the future of manufacturing
- Universal Robots launches SME automation month for October
- A key consideration for a successful robot installation
- ABB offers Augmented Reality on a smartphone to simplify robot installations
- Long reach with a high payload: Fanuc expands m-900 series
- Robot palletiser increases throughput and reduces costs
- Fanuc expands range of handling robots
- ABB’s new 3D inspection robot system makes quality control testing ten times faster
- UK’s only dedicated Universal Robots training centre to reopen after Covid-19 lockdown is eased
- Automatica and Munich School of Robotics and Machine Intelligence (MSRM) initiate AI platform munich_i
- Cobots maximise return on investment
- Festo gives the future of safe automation a hand
- Omron launches HD-1500 mobile robot with 1500kg payload capacity
- New cobot offers solution for post-lockdown manufacturing
- Fanuc UK to host dedicated automation event for injection moulders
- RS Components joins forces with VEX Robotics to set summer STEM coding challenge
- ABB makes manufacturing more sustainable by recycling and remanufacturing thousands of old robots
- Entry-level robots to kick-start new factory automation projects
- Fast entry into low-cost automation using a digital twin in intuitive robot control
- UNLOCK A NEW LEVEL OF FLEXIBILITY FOR FINISHING APPLICATIONS
- Robots speed up the production of Covid-19 tests
- Collaborative robot brings game-changing industrial performance
- ABB’s robot training masterclasses now available online
- Universal Robots offers free online consultations to Pharma companies
- UR10 cobot from RARUK Automation saves labour costs at BWI
- Do you need a collaborative robot?
- RARUK opens dedicated Universal Robots training centre
- Robots play key role in the manufacture of EV battery packs
- Safe in the robotic arms of Mitsubishi Electric
- Tending to excel with a robot ‘handshake’
- Mitsubishi launches new robot model at SPS 2019
- Mobile robot moves payloads up to 250kg
- Collaborative or cooperative: which type of robot suits your needs best?
- New support offering helps to raise productivity
- Robot versus knot – it’s a tie
- LG Motion expands into collaborative robotics
- Food cutting becomes a piece of cake
- Mitsubishi introduces range of high performance delta robots
- Can robots transform your business?
- UK Robot Pioneers win Queen’s Award for Enterprise for Innovation
- British made robots already helping UK manufacturers
- New additions bring greater robot dexterity
- Robot arms are getting everywhere
- In the future you’ll be talking to your robots
- Innovation lab shows the benefits of robots
- New dresspack configurator for virtually any robot
- Three-way concept for tool changer for all robot brands
- Yaskawa and Reeco partner in cobots
- Igus introduces delta robots at under £5,000
- Universal Robots launches new flagship cobot range
- Applied Automation adds new cobot product lines
- New cobot offers flexible and reliable support
- Optimise your production
- Should robots pay taxes?
- Standards for safety when using collaborative robots
- Should robots be taxed?
- Fanuc launches SCARA robot range for assembly, packing and material handling
- Small and cost-effective: low-cost robolink robot arm in a compact design
- Cobot force control with high sensitivity
- Collaborative automation – a guide to common applications
- Universal Robots draw the crowds in Regent Street
- ABB extends the YuMi family
- Easy transition from ‘helping hand’ to full automation
- New White Paper: Cobots – a catalyst for reshoring
- Mitsubishi extends robot range with first collaborative robot
- Six-axis robot turns 3D printing into an art form
- Automata slashes the cost of robotics
- RARUK Automation highlights robots at Advanced Engineering
- Seminar provides step-by-step guide to improving your productivity with robots
- Dual gripper speeds output and relieves tedium
- Innovative Collaborative Robot sets new benchmark
- Omron debuts world’s fastest and first 4 arm Delta robot
- Resist the urge to blame the robots
- Schunk publishes its new lathe chuck catalogue
- New collaborative robot products and applications showcased at Northern Manufacturing
- Yaskawa MotoLogix hooks up with Routeco
- Universal Robots receives ‘Best Design’ award
- Mabey puts cutting-edge ABB robots to work
- Motoman robots plus AirGrip equals a better grip on bottles
- New robot lends precision and reliability to the production of hearing aids
- One stop shop for robotics and motion
- The future is bright for robotics
- A simple guide to robot safety
- Free online training in robot programming
- Cobots driving efficiency improvements
- Low-cost robotic range simplifies complex tasks
- Collaborative robots provide burger flipping assistance
- Low cost robotic range from RS Components
- Simple guide to robot safety
- Universal Robots now certified for cleanroom applications
- Cobots key for product testing
- Open source robotics
- Low-cost robotic range available from RS simplifies complex tasks
- Seminar provides step-by-step guide to improving your productivity with robots
- Igus expands robolink D modular kit with plastic gearing
- Universal Robots racks up the benefits at Etalex
- Igus robolink D 5-axis articulated arms now available pre-assembled
- RARUK Automation appoints robot sales engineer
- Twin robots learn to live and work with each other
- Yaskawa investing in Europe for future growth
- Igus extends robolink with direct drive arms
- Universal ‘co-bots’ boosted by next-generation robot programming
- Igus humanoid open platform robot
- UCB life scientists use robots to test cells by the billion
- X-STK confirmed as Preferred Partner for Universal Robots
- ABB Robotics introduces Connected Services to improve UK productivity
- Hands up if you know one robot arm from another
- Harder, better, faster
- Robot programming via PLC is key in food plant
- Benefits of Rodriguez-supplied technologies filter through at FDC
- Delta robot with open-architecture controller
- Teradyne announces new Universal Robots president
- Universal Robots now certified for applications in cleanroom environments
- Robot automates SIM card packaging
- Low cost robots help students get up to speed
- Collaborative robots meet machine tending needs
- Igus robolink robots tend machine tools
- Omron acquires Adept’s classy robots for fast-moving automation
- Collaborative robots boost production and prevent errors
- UCB life scientists use robots to test cells by the billion
- The breakthrough of smart robots at Automatica 2016
- ABB to showcase latest robotic innovations at MACH 2016
- ABB introduces its first SCARA robot family
- Mitsubishi demonstrates MELFA SafePlus robotic safety
- From distributor to preferred partner
- AUTOMATICA 2016: Innovations for the food industry
- Applied Automation to distribute Universal Robots
- Second tea packing system ordered
- Second tea packing system ordered
- COMAU and B&R assimilate robotics into machine control
- London start-up simplifies robotic automation at a 10th of the cost
- Life sciences focus for AUTOMATICA 2016 in Munich
- 10,000 Comau robots controlled by B&R
- Modular system for safe robotics
- Path tracing robot with pattern recognition
- Safety considerations with CoBots
- Direct drive robotic arms support lean automation
- Omron acquires Adept Technology
- Fanuc robotic golf cell highlights precision and vision
- Omron demos path tracing delta robot with freehand pattern recognition
- Robot delivers 18 month ROI
- First Fanuc MC410iC/185 robot in the field at Askew & Barrett
- Aerotech introduces RCP-DELTA robot and controller
- Fanuc unveils world's highest payload collaborative robot
- Robots are on the march
- Schunk has a hand in precision gripping
- Unlocking the potential of robotic automation
- Robot 'first timer' meets exponential growth in demand
- Superior operating performance and reduced operating costs
- Sweetcorn Factory First for FANUC
- Busting the myths around robotics
- ABB acquires Gomtec to expand collaborative robotics portfolio
- Igus to offer €1500 industrial robot
- Teradyne announces Universal Robots acquisition
- Flexible product gripper
- Flexible, light-weight table-top robot
- Lightweight, table-top robot for collaborative working
- Getting a grip on collaborative robots
- Putting safety first when working with robots
- Robotics in the supply chain will enhance humans, not replace them
- Browse robot videos by company, technology or industry
- Robotics update brings the best of the web
- Using robots for bespoke and low volume processes
- robolink helps robots break free
- En route to robot safety
- Measuring robot works tirelessly outdoors
- Adaptive robot gripper system
- RA Rodriguez introduces third generation robots
- Robot gripper based on the human hand
- Tiny gripper accomplishes 3mm stroke in 0.03s
- HANNOVER MESSE showcases latest generation of industrial robots
- Picked to perfection
- Top tips for staying safe when working alongside robots
- Universal Robots launches third generation products
- New resource for industrial robot information
- Lightweight robots incorporate absolute encoders and adjustable safety
- Service robots revolutionise clean-up of the Sydney Harbor Bridge
- "Farming intelligence" creates greater value
- AUTOMATICA 2014: Focus on automobile production
- Innovations in life sciences
- Robots for metalworking
- Service Robots - Clever colleagues at work
- Service Robots - intelligent and autonomous
- Service robots in the medical industry
- Working with robots simply as automation components
- Table tennis star takes on fast, flexible KUKA robot
- Improving the state of UK manufacturing
- Mitsubishi Electric robot emulates intuitive human cake icing movements
- An innovative approach to automating ultrasonic testing
- Universal robot is a star attraction at Honda's Technical Festival
- The brains behind an effective robot solution
- The robot revolution that never quite happened...
- Table tennis legend to take on KUKA robot
- Robot transformations
- FANUC paint shop robots boost installed UK base
- An innovative approach to automation for production of airbag control sensors
- KUKA announces Siemens cooperation
- How to take control of a robot arm
- Next generation of high speed pickers
- Robot helps to get MS sufferer back to work
- Mitsubishi Electric robot picks stem cells
- Novel energy chain system increases uptime for Jaguar Land Rover
- Performance robot is food safe
- Robotics integrates with vision, motion and PLC in single platform
- Innovative robot design set to revolutionise the market
- Increase production flexibility with a robot arm tool changer
- Transforming your sustainability with robotic automation
- Huge uptake reported for automation grant
- Innovation in lightweight, low cost robotics
- Automation Brings Everything Together in the Electrical Industry
- ABB doubles investment in training centre
- Getting to grips with the bionic FinGripper
- Pick and place delta robots
- Robot night shift gives ALM a competitive edge
- Seeing your name in lights, thanks to KUKA robots
- Economical, flexible robot found after 10 year search
- Aerotech launches Cartesius T-style robots
- Automation transforms forge's finishing facility
- Compact high-speed robot requires minimal workspace
- It's time for the UK to embrace robots
- Modular robots were inspired by nature
- Robot arm tool changer is faster and stronger
- Robot range completed by six-axis launch
- Robot retrofits: Axis 1 safety
- Save assembly time and costs
- ABB robots featured in "Terminator Salvation" movie
- Bionic penguins mimic real life movement
- Energy and data supply for robotics