Rockwell Automation Enables Precision Packaging for Orphea

Packaging automation, consumer goods manufacturing, and industrial control systems are driving the modernization of end-of-line processes, as Orphea implemented a fully automated secondary packaging solution using Rockwell Automation technologies. The system addresses the complexity of handling delicate, perfume-impregnated fabric protectors while maintaining packaging quality and consistency.

Orphea, a Swiss manufacturer producing high volumes of fabric protection sheets, faced limitations due to manual packaging at the final stage of production. This step required precision handling of fragile materials and premium packaging formats, creating a bottleneck that constrained scalability and increased the risk of human error.

Automating Complex and Delicate Packaging Processes
The challenge involved automating the handling of thin, perfume-treated paper sheets and placing them into precisely designed packaging without altering product presentation. The process also required flexibility to accommodate multiple product sizes and packaging formats.

To address this, Vimco developed a customized two-stage end-of-line packaging system in collaboration with Orphea, integrating Rockwell Automation components for control, networking, and motion precision.

The first stage inserts individual fabric sheets into thin cardboard pouches and organizes them into boxes. The second stage uses an automated case packing and sleeving system to group and shrink-wrap boxes in predefined quantities, preparing them for palletization.

Integration of Vision Systems and Motion Control
The system combines multiple subsystems, including a vision system to detect product presence, position, and size, and robotic handling units capable of precise picking and placement. This enables consistent handling of delicate materials without damage.

To ensure synchronization across all components, the platform uses industrial Ethernet networking based on managed switches, enabling deterministic communication between subsystems. Precision motor control is achieved through advanced drive systems, ensuring consistent motion profiles during high-speed operations.

Digital Twin Simulation for System Optimization
Before deployment, the system was modeled and tested using digital twin software to simulate real-world operating conditions. This allowed engineers to validate motion sequences, optimize throughput, and ensure coordination between subsystems prior to installation.

This approach reduces commissioning time and minimizes operational risks, particularly in systems where multiple interdependent components must function in precise alignment.

Throughput Improvement and Production Flexibility
The automated system enables Orphea to consolidate two separate production lines into a single flexible line capable of handling multiple product formats. This is achieved through dynamic adjustment based on product size detection, allowing seamless switching without interrupting production.

By eliminating manual secondary packaging, the company removes a key bottleneck, enabling higher throughput and improved scalability. Reduced error rates also contribute to lower material waste and fewer rework cycles, improving overall production efficiency.

Workforce Impact and Operational Scaling
The transition to automation has allowed operators to shift from manual packaging tasks to higher-value roles involving system operation and supervision. This aligns with broader trends in manufacturing, where automation supports both productivity gains and workforce upskilling.

With improved control over speed, cost, and quality, the system provides a foundation for expanding product lines and increasing production volumes while maintaining consistent output standards.

Edited by Natania Lyngdoh, Induportals Editor — Adapted by AI.

www.rockwellautomation.com