A repeatable pallet for three carton formats.

A Houston packer of industrial maintenance products was building pallets manually at the end of a case-sealing line. The operation handled three carton formats weighing 12 to 24 pounds. Product arrived unevenly, and pallet patterns varied between shifts.

The required result

The customer wanted consistent pallet patterns and a sustained end-of-line rate of at least nine cases per minute across the agreed product mix. Operators still needed to supply empty pallets, remove completed loads, and change products. Those activities remained part of the production plan.

What Bayvarn supplied

Bayvarn integrated a BVX-P731 cell with two pallet positions, a vacuum gripping tool, revised conveyor accumulation, and three validated product recipes. The team tested representative cartons before finalizing the tool. It also revised the infeed sequence so the robot received each case at a consistent pick position.

Installation and acceptance

The system was assembled for a factory trial, then installed during a planned production stop. Site acceptance used a four-hour run with the three agreed carton formats. The run produced an average of 9.4 cases per minute, including the agreed pallet exchanges and product changes. No dropped cases were recorded during that test.

What the customer received

The handover included the accepted patterns, operator recovery instructions, controls backups, and a maintenance checklist. New carton formats require a handling review before production use. The customer selected Bayvarn ServiceCare Maintain for the cell and its included conveyor sections.

What the result means

The observed result applies to the tested products, layout, and operating period. It shows that the specified end-of-line sequence met the project’s acceptance conditions. The project did not include case packing, stretch wrapping, or changes to the upstream filling process.