In a groundbreaking move within the food industry, grocery wholesaler Kaufland has implemented a sophisticated robotic solution for the handling of sausages at its Fleischwaren sausage plant in Heilbronn, Germany. Tasked with loading a machine for the automated slicing of 1.5-meter-long sausages weighing 12 kilograms, the Stäubli TX200 HE six-axis robot has stepped in to relieve employees of repetitive and physically demanding work while offering several notable advantages.

Handling food products with robotics presents unique challenges, particularly concerning hygiene standards when direct contact with the product is involved. Kaufland was keenly aware of these challenges, with doubts surrounding the suitability of robotic solutions for their sausage production. Dieter Schäfer, packaging team leader at Kaufland Fleischwaren, acknowledged the unpopularity of manually loading the slicer with oversized sausages, coupled with the inability of manual processes to keep pace with evolving production demands.

However, concerns about hygiene standards and the ability of a robotic system to withstand rigorous cleaning cycles were significant hurdles. Martina Düngfelder, Local Head of Life Sciences & Food at Stäubli Robotics, Germany, addressed these concerns by highlighting the reliability and hygiene compliance of Stäubli's washdown-capable HE robots, proven over 15 years in hygiene-sensitive environments.

To further reassure Kaufland's management, Stäubli arranged visits to similar projects, demonstrating the robots' reliability under stringent hygiene requirements. With confidence in the robotic solution established, Kaufland committed to the implementation of the Stäubli robot.

Space limitations and the need for precise gripper technology presented additional challenges. Rainer Bonfig, Managing Director of bsb robot systems GmbH, emphasized the complexity of designing a gripper capable of handling multiple oversized sausages without damage, a task necessitating innovative solutions.

The resulting robot-assisted slicer loading system combines the Stäubli TX200 HE six-axis robot with a specially designed quadruple roller gripper. This gripper, weighing nearly 80 kilograms and spanning 1,800 millimeters in width, ensures the safe and precise transfer of sausages to the slicer without compromising product integrity.

The successful implementation of this robotic solution has significantly enhanced production efficiency at the Kaufland facility. With an output of 12,000 kilograms of sliced sausage per day achieved in two-shift operation, the system handles 21 different types of sausage, catering to markets in Germany and Eastern Europe.

Dieter Schäfer, once skeptical, now advocates enthusiastically for the robotic cell, citing its ability to meet strict hygiene standards, alleviate employee workload, increase productivity, and withstand intensive cleaning processes. The project represents a comprehensive success in optimizing sausage production processes at Kaufland Fleischwaren.

In summary, Kaufland's adoption of robotic technology for sausage handling underscores the potential of automation to address challenges in the food industry, offering efficiency gains while maintaining stringent hygiene standards.