The Challenge
Optimizing Depalletizing Workflows in Restricted Brewery Space
The firm’s existing semi-automatic depalletizing process relied on manual case handling—leading to repetitive strain injuries and throughput bottlenecks. Constraints included:
- Frequent worker injuries due to repetitive manual case handling
- Limited vertical space requiring low-profile equipment
- Incoming pallets delivered at half-height, reducing efficiency
- Need to unload full pallets quickly while maintaining case orientation
MWES was selected to design a robotic system capable of operating within tight height limits while handling full-height pallets and improving depalletizing safety and speed.
The Solution
Low-Profile KUKA Robot Cell with Vacuum Layer Gripper & Vision Guidance
MWES implemented a turnkey system comprising:
- KUKA robot optimized for operation under a low ceiling beam
- Vacuum EOAT picks entire layers of up to 540 lbs worth of cases per cycle
- Vision system ensures correct case orientation via conveyor singulation
- Automated pallet pusher, case dispensing conveyor, and pallet stacker for emptied pallets
- Operator loads pallets via forklift and selects case type via HMI interface
The system was engineered to handle full-height pallets in confined overhead space while automating layer picking and case orientation using vision-enabled robotics.
The Results
20 % Throughput Boost, Improved Worker Safety & Full-Pallet Capability
The MWES solution delivered immediate operational improvements:
- Achieved 3.5–4 pallet layers per minute, increasing throughput by 20 %
- Eliminated repetitive motion strain by removing manual case handling
- Allowed full‑height pallet operation even in low-clearance areas
- Delivered consistent case orientation and processing reliability across mixed SKUs
By combining compact robotics, layer grippers, and vision control, MWES enabled safer, faster pallet breakdown and higher throughput with full-pallet capability in constrained environments.
