Case Study: Automatic Emptying Feature for Aggregated Batch

This case study discusses the implementation of SEA Vision's automatic emptying feature for a pharma manufacturer client in Europe. Using Track & Trace system on the MC820 packaging machine, the solution aimed to optimize efficiency during end-of-batch operations. The automatic emptying functionality streamlined processes by ensuring every carton was correctly serialized and aggregated, eliminating the need for human intervention when packing partial cases. 

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Challenge

At the end of a serialized batch packaging operation, it’s common for the cartons coming from the labeller to the case packer to be fewer than required to fully fill the case.

Typically, the last cartons in a batch are packed and serialized by the operator using a handheld scanner, which can slow down line efficiency, increase error risk, and add complexity to the line clearance process.

Solution

To solve these issues, Marchesini Group and SEA Vision developed an automatic emptying feature that allows the automatic aggregation of a final, partially filled case. This feature, enabled by advanced automation and control functions, ensures that even the last carton is automatically picked up and serialized without manual intervention.

The benefits of this solution include:

• Increased Efficiency: Reduced time to fill the last case in a batch, maximizing production output.
• Improved Safety: No human intervention is needed, minimizing the risk of errors and enhancing process reliability.
• Streamlined Line Clearance: Ensures the machine is entirely empty at the end of each batch, simplifying line clearance, increasing production efficiency, and supporting regulatory compliance.

The seamless integration between the Marchesini Group’s case packer and SEA Vision’s Track & Trace solution enables precise signal exchange and automation capabilities. This new feature, initially installed on the MC820 model, has since been extended to other Marchesini case packer and palletizer models.

How the System Works

At the end of each batch, when the final cartons are at the case packer infeed, the operator activates the emptying feature on the HMI to begin the automatic conveyor belt emptying process.  

The case packer then picks up the remaining cartons, managing a final partial row down to a single carton if needed, automatically.

SEA Vision's Tracker - its Track & Trace solution at the line and machine level - is equipped with four cameras that verify the serialized codes of each row of cartons. If an error is detected, such as an incorrect or missing code, the machine automatically rejects that row.   In real-time, the results are displayed, allowing operators to easily reintegrate any correct cartons from a rejected row.

Specially Designed Control for Partial Rows
To ensure a partial row (even down to a single carton) can be processed accurately, a new control feature has been introduced. Under standard conditions, if a carton in a row has an unreadable code, the entire row would typically be rejected. With the emptying feature enabled, this control is adjusted to prevent the entire row from being discarded unnecessarily. A newly added distance sensor positioned behind the pickup measures the last picked-up carton’s distance from a fixed point, helping to count cartons precisely.

Tracker compares this count against the number of read codes. If they match and all codes are valid, the cartons are aggregated into the case. This ensures 100% accuracy, allowing only rows with missing or incorrect codes to be rejected.

When the last carton is picked up, the system manages label printing for the partial case, clearly marking the quantity of cartons inside. The Tracker solution then finalizes the aggregation of cartons to the case.

Results

The entire aggregation process from the first to the last carton is now faster, more accurate, and free of manual intervention.

Other Applications

The new automatic emptying function for aggregated batches has also been installed on various Marchesini models, including the MCP840 case packer/palletizer. This model can automatically package the final partial pallet, ensuring smooth aggregation down to the last carton.

Learn More

For further information about SEA Vision's Track & Trace solution and Marchesini Group’s MC820 case packer, visit:

• SEA Vision Track & Trace Solution
• Marchesini Group MC820 Case Packer
• Marchesini Group MCP840 Case Packer Palletizer