Back to case studies
Automating End-of-Line Bottle Feeding with High-Speed Circular Tracking
Medical
Packaging
i4H SCARA Robot
A compact robotic cell replaces manual bottle handling in medical diagnostics packaging
In medical diagnostics packaging, end-of-line bottle feeding is often still handled manually or with conventional mechanical systems that are difficult to adapt. For Samas Italy, this created a clear bottleneck: repetitive manual work, limited flexibility across formats, and reduced continuity at the final stage before flow-pack and cartoning machines. The goal was to automate this part of the line without adding complexity or requiring a large machine footprint.
To solve it, Samas developed a compact circular-tracking cell together with OMRON, combining i4H SCARA robots, the FHV7 vision system, 1S servo drives and motors, and an NJ-series controller within the Sysmac architecture. Using the OMRON Robotics Packaging Library (ORPL), the robot can identify bottles on a rotating ring, track them in motion, and place them onto a synchronized linear conveyor in a single continuous sequence. This creates a compact robotic end-of-line packaging solution with precise motion control, reduced mechanical complexity, and predominantly digital format changeovers.
The result is a faster, more flexible bottle feeding process with throughputs of 50–60 parts per minute, reaching up to 80 parts per minute in some configurations. Repetitive manual end-of-line operations are drastically reduced, process reliability is improved, and changeovers can be completed quickly with minimal mechanical adjustment. For Samas, the project closed a critical automation gap while creating a scalable solution for regulated industries where reliable, high-mix packaging is essential.
Watch Samas’ solution in action:
“Beyond our initial expectations, we managed to further increase machine speed. Most importantly, we truly completed line automation from start to finish, eliminating a critical manual bottleneck.” — Marco Alfani, CEO of Samas
Results at a glance:
- Up to 80 parts per minute in automated bottle feeding
- 50–60 parts per minute in standard operating configurations
- Drastic reduction of repetitive manual operations at the end of the line
- Predominantly digital, fast format changeovers with minimal mechanical intervention
- Compact footprint suited to space-constrained production environments
- Improved process reliability and reduced waste
- Fast ROI through lower labor and operating costs
Smarter bottle handling for regulated packaging lines
This application shows how end-of-line bottle handling can be automated to reduce manual work, increase throughput, and simplify changeovers without adding unnecessary complexity. In lines handling multiple bottle formats, it helps remove a persistent bottleneck and improves the transfer into cartoning, flow-wrap, and other downstream packaging processes.
By combining a compact footprint with flexible operation, the solution helps manufacturers improve line continuity, make better use of floor space, and build a more efficient packaging process. Speak with our team about your application and explore how a tailored automation solution could improve throughput, reduce manual handling, and support more flexible packaging operations.
Back to case studies
Book a consultation
