From strain to smart automation: How CAVAC transformed palletizing with collaborative robotics

E-Cobot

E-Cobot integrates a solution for palletizing legume bags at CAVAC

In short

E-COBOT, a certified Universal Robots integrator based in the Pays de la Loire region, has developed an automated solution for palletizing bags of dried vegetables on behalf of CAVAC, an agricultural cooperative group. Integrated into its new production site in Mouilleron-le-Captif in Vendée, the cobotic cell operates almost autonomously. The benefits observed include improved throughput, increased precision, and reduced strain on the workstation concerned.

A painful process in need of change

When CAVAC opened its new production site for packaging dried vegetables, the company wanted to modernize operations, improve working conditions, and increase efficiency. One task stood out as a priority for change: palletizing bags of legumes. Previously, operators manually lifted and placed 120 heavy 5 kg bags into pallet boxes every hour. This was physically exhausting and carried a high risk of injury and musculoskeletal disorders. It also kept workers tied to repetitive tasks that added little value to their skills or the business. The bags were soft and fragile, so they needed to be handled with care and placed according to a precise palletization plan. The solution also had to work in a small space and be completely safe without the need for bulky physical barriers. To achieve this, CAVAC partnered with E-COBOT, a Certified Systems Integrator for Universal Robots in western France. After visiting the site, E-COBOT began developing a solution that combined robotic efficiency with operator safety and comfort.

E-Cobot

Industry Food and Beverage

Country France

Number of employees 30

Cobot used UR10e

Main value drivers:

Simplicity and intuitiveness of the solution
Almost autonomous operation
Increased productivity

Tasks solved by collaborative robots:

Palletizing bags of legumes

Automation challenges solved:

Adaptation of the cobot according to the palletization plan
Reduction of MSDs among operators
Integration in record time into the workshop
Time saving for the operator

How they did it

A tailor-made robotic solution

E-COBOT designed a custom palletizing cell using a UR10e collaborative robot. The system included a specially adapted Joulin gripper to handle the size, weight, and fragility of the bags, along with Robotiq’s PE10 application kit for lifting and palletizing control.

A safety assessment by a certification body resulted in CE marking for the installation. The setup uses 360-degree scanners to monitor two safety zones. The robot slows down if someone steps into the first zone and stops completely if the second zone is entered. This allowed the cobot to operate safely without taking up extra space with physical barriers.

The cobot uses pneumatic suction to pick up each 5 kg bag from the conveyor and place it carefully into boxes, avoiding contact with the sides. Every detail, from box size and placement to bag grip points, was configured for accuracy and repeatability.

When the first box is filled, the cobot moves to the second. Once both are full, a light signal alerts the operator to remove them for transfer to the packaging area. The system can also be bypassed to package lighter 2 kg mesh bags on the same line.

We developed a cobotic palletizing solution that was fully adapted to the needs of CAVAC. The challenge was to accurately place 5 kg bags into pallet boxes without damaging them. It also had to integrate seamlessly into the brand-new workspace, all while ensuring complete operator safety.

Aymeric Charraud, Cobotics Project Manager at E-COBOT

able to palletize up to 600 kg of bags in just 15 minutes

Stronger, safer, and more productive

The new palletizing solution removed the most physically demanding part of the job. Operators no longer lift 600 kg of bags every hour, reducing the risk of injuries and work stoppages. They can now focus on more valuable activities such as supplying, stocking, and palletizing lighter net bags.

The system is also highly productive, able to palletize up to 600 kg of bags in just 15 minutes. It delivers consistent precision while protecting the delicate products.

For CAVAC, the installation has become a symbol of its modern, forward-looking workshop. It serves as a practical example of how Industry 4.0 technology can improve safety, boost productivity, and create a better working environment.

The operator starts the palletizing process via the cobot's tablet

The gravy-filled bag moves along a conveyor, is labeled and it's weight is checked

A sensor at the end of the conveyor signals the cobot when the bag arrives

600 kg of bags are placed in a pallet box by pneumatic suction with a vacuum gripper, according to a precise and repeatable palletizing plan

when the first box is filled, the cobot repeats the operation for the second

once the process is complete, it stops automatically and alerts the operator with a light signal

the operator sends the filled boxes to packaging via a pallet truck and starts a new cycle

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