Did you know that manufacturers operating in high-mix, low-volume production environments often face some of the toughest automation challenges? Frequent product changeovers, varying packaging formats, strict hygiene requirements, and labor shortages can make maintaining efficiency and consistency difficult.
As a high-mix manufacturer, GM Pack needed an automation solution capable of handling a wide variety of container formats without lengthy changeovers or complex programming. The company wanted to reduce repetitive manual handling tasks while improving process consistency, product quality, and hygiene standards. At the same time, GM Pack was looking for a way to increase production flexibility and scale operations without introducing additional labor-intensive processes. A critical requirement was the ability to reliably grip and handle containers of different sizes, shapes, and materials throughout the filling and capping process.
"Flexibility is critical for our business," says Christian T. Kjærgaard, CEO of GM Pack. "We handle many different container sizes and formats, and the OnRobot grippers allow us to use the same automation platform across multiple products. That means we can adapt quickly to changing customer requirements without adding complexity to our operations."
To minimize the risk of human error while increasing production capability, flexibility and scalability, GM Pack implemented three automated Cream Filling Solution developed by Technicon.
Each Crème Fillling Cobot incorporates two Universal Robots equipped with OnRobot intelligent tooling to automate the handling, filling, and packaging process.
While one station picks and positions empty containers for accurate filling, the second performs the capping operation, ensuring a consistent and efficient production flow.
A key requirement for this application was the ability to handle a wide variety of container sizes and formats while maintaining high accuracy and enabling fast changeovers between production runs. To achieve this, GM Pack selected the OnRobot Quick Changer, which plays a critical role in achieving that goal by providing fast tool changes in less than 5 seconds.
"The OnRobot Quick Changer has been a major advantage for us. Being able to switch between grippers in seconds gives us the flexibility to move between products and applications with minimal interruption. It helps us maximize uptime while maintaining the agility our customers expect."
As a fully electric gripper, the 3FG25 eliminates the need for external compressed air, reducing operating costs, simplifying installation, and lowering maintenance requirements. This allows GM Pack to deploy automation more easily across multiple production processes while maintaining the flexibility to adapt to changing product and packaging requirements.
With flexible gripper technology at the center of its automation strategy, GM Pack has increased production efficiency, reduced manual handling, and improved process consistency. The ability to quickly switch between products and packaging formats enables faster changeovers thanks to OnRobot Quick Changer and easier redeployment across multiple applications, supporting the company's high-mix, low-volume production model.
With two OnRobot 3FG25 grippers, GM Pack ensured stable, accurate, and repeatable handling across a wide range of container types. Its intelligent three-finger design with customized fingers enables reliable gripping of different container sizes and shapes, making it an ideal solution for GM Pack's high-mix production environment. Accurate centric positioning helps maintain consistent product quality throughout the filling and packaging process, while the gripper's out-of-the-box usability significantly reduces deployment time and simplifies implementation.
"Consistency is extremely important in our industry," says Kjærgaard. "The OnRobot grippers provide reliable and repeatable handling of our containers, which helps us maintain product quality and process stability. At the same time, reducing manual handling supports the high hygiene standards that are essential in our production environment."
At the same time, the solution helps maintain the high hygiene standards required in GMP-regulated environments while providing the flexibility, scalability, and cost efficiency needed to support future growth.
Technicon is among the leading integrators when it comes to flexible and innovative automated solutions designed and developed to improve flow in complex environments where the requirements for quality and hygiene are crucial.
Founded in 2001 in Hadsund, Denmark, GM Pack is a GMP-certified contract manufacturer specializing in the development, filling, packaging, and distribution of pharmaceuticals, dietary supplements, natural herbal remedies, and skincare products. Serving both private-label customers and its own skincare brand, Beauté Pacifique, GM Pack combines strict quality standards, regulatory compliance, and flexible manufacturing capabilities to support customers worldwide.