Industrial producers typically battle with capability, labor pressure, and consistency.
At Korea Filter Engineering, handbook palletizing of 10–20 kg (22-44 lb) industrial filter containers was limiting output, rising ergonomic threat, and slowing deliveries.
After deploying the Robotiq PE20 with a UR20, the corporate achieved:
- 30% manufacturing improve
- 50% discount in employee fatigue
- Close to 50% discount in injury-related absences
- Zero office incidents since set up
- ROI anticipated inside 2 years
This case research reveals how collaborative robotic palletizing improves productiveness whereas defending employees in heavy-load manufacturing environments.
Firm overview: Industrial filter manufacturing in South Korea
Based in 1996 and primarily based in Gimpo, Korea Filter Engineering manufactures industrial filters utilized in electrical discharge machining (EDM).
- Trade: Industrial filter manufacturing
- Staff: 15
- Every day palletizing load (earlier than automation): ~4 tons
- Field weight: 10–20 kg
With a lean workforce and rising demand, handbook palletizing turned a manufacturing bottleneck.
The problem: Handbook palletizing of heavy containers
Earlier than automation, employees manually lifted and stacked roughly 4 tons of product per day.
Key points included:
1. Ergonomic threat and employee fatigue
- Repetitive lifting of 20 kg containers
- Again, shoulder, and muscle pressure
- Getting older workforce rising harm threat
- Fatigue affecting morale and consistency
2. Productiveness limitations
- Every day output capped at 200 containers
- Delays brought on by bodily pressure and absenteeism
- Problem sustaining constant throughput
3. Failed options
Earlier lifting aids have been examined however operations repeatedly reverted to totally handbook palletizing attributable to complexity or inefficiency.
The corporate wanted an answer that was:
- Compact
- Steady
- Straightforward to function
- Secure for human-robot collaboration
- Fast to deploy
The answer: Robotiq Lean Palletizing
In early 2025, Korea Filter Engineering chosen the Robotiq PE20 palletizer built-in with the UR20 collaborative robotic.
Why this palletizing system?
- Handles containers as much as 20 kg
- Helps as much as 20 SKUs
- Most pallet top: 2130 mm (84 in)
- Compact footprint for space-constrained amenities
- Works alongside staff with out intensive security fencing
- Intuitive interface requiring minimal coaching
Quick deployment timeline
- Early 2025: Analysis
- March 2025: Citation
- Might 2025: Set up and launch
Minimal format modifications have been required. The system built-in seamlessly with the present conveyor.
Operators have been in a position to be taught and run the system inside minutes, decreasing dependency on specialised robotics experience.
Outcomes: Measurable features in productiveness and security
1. 30% manufacturing improve
- Output elevated from 200 to 250 containers per day
- Greater throughput with out rising headcount
- Improved supply reliability
2. Improved employee well being and security
- Damage-related absences almost halved
- Employee fatigue diminished by greater than 50%
- Zero office incidents since set up
Younger-Hun Yoo, Assistant Supervisor in Manufacturing, shared:
“After utilizing the robotic, our our bodies are more healthy, and we really feel much less drained—lower than half in comparison with earlier than. We have now extra vitality left for our households after work.”
3. Workforce optimization
- One full-time worker reassigned to higher-value duties
- Much less bodily pressure, extra operational focus
- Stronger staff morale
4. Sturdy monetary case
- Anticipated return on funding inside 2 years
- Diminished oblique prices associated to harm and absenteeism
- Elevated capability with out increasing facility area
Why collaborative robotic palletizing works in heavy manufacturing
This venture demonstrates key benefits of cobot palletizing programs:
Protects employees from repetitive heavy lifting
Eradicating 4 tons of each day handbook lifting dramatically reduces ergonomic threat.
Will increase output with out increasing workforce
Automation dietary supplements labor as a substitute of changing it.
Scales with product variability
The PE20 handles as much as 20 SKUs, supporting various product traces.
Suits in space-constrained amenities
Compact design makes it viable for small and mid-sized producers.
Allows quick ROI
Measurable productiveness and security enhancements speed up payback.
Woo-Seok Kim, Director of Enterprise, defined the choice:
“We checked many robotic programs, however the PE20 was essentially the most steady. Defending our employees is crucial factor, and the PE20 permits us to try this. That’s the reason it’s definitely worth the funding.”
Key takeaways for producers contemplating automation
In case your operation entails:
- Handbook palletizing of heavy containers
- Repetitive lifting inflicting fatigue or accidents
- Labor shortages or growing old workforce challenges
- Restricted flooring area
- Productiveness plateaus attributable to bodily constraints
Collaborative palletizing automation could ship speedy, measurable impression.
Korea Filter Engineering’s transformation proves that producers should not have to decide on between:
- Productiveness and security
- Progress and workforce wellbeing
- Automation and operational stability
With the fitting palletizing answer, you possibly can obtain all three.
Is Lean Palletizing the fitting match in your manufacturing line?
Use Robotiq’s Palletizing Match Software to rapidly assess whether or not cobot palletizing is sensible in your operation and what a practical deployment may seem like in your facility. You may even get customized estimates for ROI and payback durations and a 3D simulation of what Lean Palletizing may seem like in your manufacturing unit flooring.
