Your corrugated packaging operation faces daily challenges with manual dunnage placement – protective material sheets positioned between stacks of corrugated boards. This labor-intensive process slows production, risks worker safety, and creates inconsistent results. The TopBot system from 20/20 Robotics transforms this operation through robotics and machine vision technology.
Revolutionizing the Last Manual Operation on the Corrugator
Manual dunnage placement remains one of the final non-automated processes on most corrugator lines. Workers must quickly position protective sheets between stacks while keeping pace with high-speed production – a task that leads to fatigue, potential injuries, and production bottlenecks. TopBot eliminates these challenges by automating dunnage placement onto corrugated sheet stacks and bundled units, delivering precise positioning that improves your product quality and worker safety.
Key Benefits of TopBot Implementation
Increased Speed and Efficiency
TopBot matches your high-speed production requirements, completing dunnage placement cycles in 15 seconds. The system processes more than 200 units per hour, synchronized with standard corrugator strapping equipment speeds of 180-220 units hourly. This speed maintains consistent flow on your production line while eliminating manual placement bottlenecks.
Superior Placement Accuracy
Precise robotic control positions each dunnage sheet within 1/22 inch of specified targets. Real-time adjustments maintain this accuracy throughout production runs, reducing waste from misaligned placement and improving stack stability during shipping.
Advanced 3D Vision Systems
TopBot uses industrial cameras and laser sensors to create detailed 3D maps of each stack. This technology measures stack dimensions and automatically adjusts dunnage placement, maintaining perfect positioning even when product specifications change. The system adapts to stack heights up to 72 inches and widths up to 98 inches without manual adjustment.
Reduced Labor Dependencies
By automating dunnage placement, you can reassign workers from repetitive manual tasks to higher-value operations. Your facility saves on direct labor costs while creating opportunities for staff advancement. The reduction in manual handling decreases workplace injuries, particularly repetitive strain and back injuries common in manual dunnage placement.
Transforming Production Lines
TopBot integrates with your existing corrugator line while meeting all safety requirements. The system includes comprehensive guarding, emergency stops at key points, and CE/UL safety certifications. Your workers remain protected through automated zone monitoring that prevents access during operation.
Quality improvements come from TopBot’s consistent placement accuracy. Your stacks maintain stability through shipping, reducing product damage claims and returns. The system logs placement data for quality tracking, helping you document consistency improvements.
Expert Integration and Support
Successful automation requires expert implementation and ongoing support. At 20/20 Robotics, your dedicated project team analyzes your current operations and develops an integration plan that minimizes disruption. Standard installation takes 3-5 days, with comprehensive operator training completed in 2-3 days. Your team receives technical support and quarterly maintenance visits to maintain peak performance.
Ready to transform your dunnage placement process? Contact our automation experts today:
- Call: 708.887.8650
- Email: solutions@2020robotics.com
- Learn more: https://www.2020robotics.com/dunnage-topbot/
Frequently Asked Questions
How long does TopBot installation take?
A typical installation requires 5-7 days for mechanical setup and integration. Your production line downtime is limited to 2-3 days through careful pre-installation preparation.
What maintenance does TopBot require?
The system needs quarterly preventive maintenance visits, including vision system calibration, mechanical inspections, and safety system verification. Daily maintenance takes 10-15 minutes for basic checks and cleaning.
Can TopBot handle different product sizes?
Yes. The system handles stack heights from 2 to 72 inches and widths up to 98 inches. Changeover between sizes happens automatically through the vision system with no manual adjustment needed.
What is the ROI timeline for TopBot?
Most facilities see full ROI in 18-24 months through labor savings, reduced product damage, and improved throughput. A facility running two shifts typically saves $120,000-$150,000 annually in direct labor costs alone.
How does TopBot integrate with existing systems?
The system connects directly to your line PLC through standard industrial protocols. It requires a 480V power supply and 90 PSI compressed air. The total footprint is 12′ x 8′, with flexibility in layout to match your space.
What training do operators need?
Operators complete a 2-3 day training program covering daily operation, basic maintenance, and troubleshooting. The touchscreen interface uses simple graphics and clear instructions, making operation straightforward for your team.
